Method and system for failure management of a die-cast door body

Abstract

The application discloses a kind of door body die casting's fault management method and system, the present application relates to the technical field of fault management, according to the service life of door body die casting and fault state diagram determine the fault level of door body die casting;Based on the fault level of door body die casting and the form of door body die casting determines the fault management event, the maintenance condition of different stages of multiple fault areas is presented, guarantee the accuracy of fault management event.Therefore, in the fault management event, based on the overall maintenance progress of door body die casting and the maintenance time target of preset triggers the autonomous control of the maintenance progress of multiple fault areas;If multiple door body die castings are in synchronous maintenance state, the use order of multiple door body die castings is collected, and the configuration of the current maintenance personnel is optimized according to the use order of multiple door body die castings and the overall maintenance progress of multiple door body die castings, guarantee the accuracy of door body die casting fault management.

Description

Technical Field

[0001] This invention relates to the technical field of fault management, and in particular to a fault management method and system for die-cast door components. Background Technology

[0002] With the development of technology, door die-casting parts, as one of the die-casting parts for new energy vehicles, are configured in the door body of new energy vehicles. Door die-casting parts are made of aluminum. In the existing technology, door die-casting parts have multiple fault areas due to damage to new energy vehicles. When maintaining door die-casting parts, it is necessary to maintain multiple fault areas one by one. However, the fault level and shape of the door die-casting parts are not taken into account, and the accuracy of fault management events of door die-casting parts cannot be guaranteed. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art. This invention provides a fault management method and system for door die-casting parts.

[0004] This invention provides a fault management method for door die-castings, comprising: identifying multiple fault areas based on the recognition of the current image of the door die-casting; determining a fault state diagram of the door die-casting based on the mechanical analysis of the multiple fault areas; determining the fault level of the door die-casting based on the fault state diagram and the service life of the door die-casting; determining fault management events based on the fault level and the morphology of the door die-casting, wherein the fault management events represent different stages of maintenance status of the multiple fault areas; in the fault management events, determining the overall maintenance progress of the door die-casting based on the maintenance progress of the multiple fault areas; triggering autonomous adjustment of the maintenance progress of the multiple fault areas based on the overall maintenance progress of the door die-casting and a preset maintenance time target; if multiple door die-castings are in a synchronous maintenance state, collecting the usage sequence of the multiple door die-castings, and optimizing the current configuration of maintenance personnel based on the usage sequence of the multiple door die-castings and the overall maintenance progress of the multiple door die-castings.

[0005] This invention provides a fault management system for die-cast door components. The fault management system is applied to the aforementioned fault management method for die-cast door components. The fault management system includes:

[0006] The fault area module is used to identify multiple fault areas based on the recognition of the current image of the door die-casting part;

[0007] The fault level module is used to determine the fault state diagram of the door die casting based on the mechanical analysis of multiple fault areas, and to determine the fault level of the door die casting based on the fault state diagram and the service life of the door die casting.

[0008] The fault management module is used to determine fault management events based on the fault level and shape of the door die casting. These fault management events represent the maintenance status of different stages in multiple fault areas.

[0009] The maintenance progress module is used to determine the overall maintenance progress of the door die-casting part based on the maintenance progress of multiple fault areas in the fault management event, and to trigger the autonomous adjustment of the maintenance progress of multiple fault areas based on the overall maintenance progress of the door die-casting part and the preset maintenance time target.

[0010] The optimization module is used to collect the usage sequence of multiple door die-castings if they are under synchronous maintenance, and optimize the current maintenance personnel configuration based on the usage sequence and the overall maintenance progress of the multiple door die-castings.

[0011] Compared with the prior art, the beneficial effects of the present invention are:

[0012] In this embodiment of the invention, multiple fault areas are determined based on the recognition of the current image of the door die-casting using the method described in this embodiment; a fault state diagram of the door die-casting is determined based on the mechanical analysis of the multiple fault areas; the fault level of the door die-casting is determined based on the fault state diagram and the service life of the door die-casting; and a fault management event is determined based on the fault level and morphology of the door die-casting. This fault management event represents the maintenance status at different stages of multiple fault areas, taking into account both the fault level and the morphology of the door die-casting, thus ensuring the accuracy of the fault management event.

[0013] Therefore, in fault management events, the overall maintenance progress of the door die-casting is determined based on the maintenance progress of multiple fault areas. Based on the overall maintenance progress of the door die-casting and the preset maintenance time target, the autonomous adjustment of the maintenance progress of multiple fault areas is triggered. If multiple door die-castings are under synchronous maintenance, the usage sequence of multiple door die-castings is collected. Based on the usage sequence of multiple door die-castings and the overall maintenance progress of multiple door die-castings, the current configuration of maintenance personnel is optimized. This approach combines the autonomous adjustment of the maintenance progress of multiple fault areas with the optimization of the current configuration of maintenance personnel, ensuring the accuracy of fault management for door die-castings. Attached Figure Description

[0014] Figure 1 This is a flowchart illustrating the fault management method for door die-cast parts in an embodiment of the present invention;

[0015] Figure 2 This is a flowchart illustrating step S11 in the fault management method for door die-casting parts in this embodiment of the invention.

[0016] Figure 3This is a flowchart illustrating step S12 in the fault management method for door die-cast parts in this embodiment of the invention.

[0017] Figure 4 This is a flowchart illustrating step S13 in the fault management method for door die-cast parts in this embodiment of the invention.

[0018] Figure 5 This is a flowchart illustrating step S14 in the fault management method for door die-cast parts in this embodiment of the invention.

[0019] Figure 6 This is a flowchart illustrating step S15 in the fault management method for door die-casting parts in this embodiment of the invention.

[0020] Figure 7 This is a schematic diagram of the structural composition of the fault management system for the door die-casting component in an embodiment of the present invention. Detailed Implementation

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

[0022] Please see Figures 1 to 7 A fault management method for die-cast door components, comprising:

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

[0024] Step S12: Determine the fault state diagram of the door die casting based on the mechanical analysis of multiple fault areas, and determine the fault level of the door die casting based on the fault state diagram and the service life of the door die casting.

[0025] Step S13: Determine the fault management event based on the fault level and morphology of the door die casting. The fault management event represents the maintenance status at different stages of multiple fault areas.

[0026] Step S14: In the fault management event, determine the overall maintenance progress of the door die casting based on the maintenance progress of multiple fault areas, and trigger the autonomous adjustment of the maintenance progress of multiple fault areas based on the overall maintenance progress of the door die casting and the preset maintenance time target.

[0027] Step S15: If multiple door die-casting parts are under synchronous maintenance, collect the usage sequence of the multiple door die-casting parts, and optimize the current maintenance personnel configuration based on the usage sequence of the multiple door die-casting parts and the overall maintenance progress of the multiple door die-casting parts.

[0028] refer to Figure 2 In step S11, multiple fault areas are determined based on the recognition of the current image of the door die-casting.

[0029] In the specific implementation of this invention, the specific steps are as follows:

[0030] S111: After the door die-casting is damaged, it is moved to the shooting area and a circular shot is taken of the door die-casting to collect the current image of the door die-casting;

[0031] S112: Based on the detection of the current image of the door die casting, identify multiple surface abnormal regions, and determine the overall abnormal region based on the multiple surface abnormal regions and the surface morphology of the door die casting;

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

[0033] In the embodiments of this application, after the door die-casting is damaged, it moves to the shooting area and performs a circular shooting of the door die-casting to acquire the current image of the door die-casting, thus introducing the current image of the door die-casting.

[0034] At this point, on the production line or in the maintenance area, the door die-casting is identified for damage through manual inspection or an automatic detection system. Damage manifests as cracks, deformation, surface scratches, dents, etc. Once damage is identified, the door die-casting is moved from its current position to a dedicated shooting area using automated handling equipment (such as robotic arms or conveyor belts) or manually. 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 rotating camera brackets to take 360-degree circular shots of the door die-casting; each camera or shooting angle should cover a part of the door die-casting to ensure that the entire surface can be captured; the camera should have high resolution and be able to clearly capture the details of the door die-casting surface.

[0036] The image data captured by the camera is transmitted to an 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 die-cast door body should be ensured to reduce the complexity of image processing.

[0037] Specifically, suppose that on a door die-casting production line in a car manufacturing plant, a door die-casting part develops surface cracks due to a mold problem during the die-casting process; the automatic detection system on the production line identifies this damaged door die-casting part using machine vision technology; subsequently, a robotic arm picks up the damaged door die-casting part from the production line and smoothly moves it to a dedicated imaging area; the imaging area is equipped with four high-resolution cameras, located on the four sides of the door die-casting part, forming a closed circular imaging system.

[0038] When the die-cast door body was placed in the center of the shooting area, four cameras were activated simultaneously to take a 360-degree circular shot of the die-cast door body. Each camera captured detailed images of the surface of the die-cast door body, including information such as the location, shape, and size of cracks. This image data was 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 identified based on the detection of the current image of the door die-casting, and the overall abnormality area is determined based on the multiple surface abnormality areas and the surface morphology of the door die-casting; the overall consideration of multiple surface abnormality areas and the surface morphology of the door die-casting is taken into account to ensure the accuracy of the overall abnormality area.

[0040] At this point, the current image of the die-cast door body acquired in step S111 is analyzed; edge detection, texture analysis, color comparison and other techniques are used to identify abnormal areas in the image. These abnormalities are manifested as color changes, inconsistent textures, distorted shapes or discontinuous edges, etc.; the identified abnormal areas are marked on the image and their location, size and shape are recorded.

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

[0042] Specifically, in step S111, a 360-degree circular image of the damaged door die-casting has been acquired; next, in step S112, image processing software is used to analyze these images; the software first applies edge detection technology to identify edge changes in the image, especially those edges that contrast sharply with the surrounding area; in this process, the software successfully identified a thin crack on the surface of the door die-casting, which started from one edge of the door and extended a certain length along the surface.

[0043] Then, the software further analyzed the crack by combining the surface morphology of the door die-casting. Since the door die-casting is a component with a complex curved surface, the software took into account the possibility that the crack would propagate along the stress concentration area. By comparing the direction of the crack with the curvature change of the door surface, the software confirmed that the crack was indeed related to a stress concentration area of ​​the door. Finally, the software marked the crack as an overall abnormal area and recorded its location, length, width, and other characteristics. This information provided an important basis for subsequent fault analysis and handling.

[0044] Therefore, after the door die-casting is damaged, multiple impact locations are marked. Multiple first fault locations are determined based on the multiple impact locations and the overall abnormal area. Multiple second fault locations are determined based on the multiple impact locations and the surface morphology of the door die-casting. Multiple fault areas are determined based on the mapping relationship between the multiple first fault locations, the multiple second fault locations and the area. This overall consideration of multiple first fault locations, multiple second fault locations and the area mapping relationship ensures the accuracy of multiple fault areas.

[0045] At this point, after the door die-casting is damaged, the impact location is identified and recorded through manual inspection or by using testing tools (such as impact testing, ultrasonic testing, etc.). The impact location is a clear dent, scratch, or deformation area, which is also an impact mark found through internal inspection. Each impact location should be accurately marked on the door die-casting or its corresponding image / model for subsequent analysis.

[0046] Determine multiple first fault locations: compare the marked impact locations with the overall abnormal area determined in step S112; if an impact location overlaps with or is adjacent to the overall abnormal area, it is considered a first fault location; the first fault location represents the damage 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 die-cast door body; analyze factors such as stress distribution and material property changes around the impact location to predict failure modes such as crack propagation and deformation aggravation; based on these predictions, identify additional secondary failure locations outside the impact location.

[0048] Establish a 3D model or image mapping relationship for the die-cast door body, and map the first and second fault locations into the model; based on the distribution, size, and shape of the fault locations, merge adjacent or similar fault locations into a fault region; each fault region should be assigned a unique identifier for subsequent management and analysis.

[0049] Specifically, in the previous steps, the overall abnormal area and impact location on the die-cast door body have been identified. In step S113, two obvious impact locations on the die-cast door body were first marked, namely the lower left corner and the upper right corner of the door body. Both locations have obvious dents and scratches. Next, these two impact locations were compared with the overall abnormal area. It was found that the impact location at the lower left corner overlapped with a crack that started to extend from the edge of the door body, so it was regarded as a first fault location. Although the impact location at the upper right corner only appeared to have slight scratches on the surface, ultrasonic testing revealed that a tiny crack had already formed inside, so it was also regarded as a first fault location.

[0050] Then, the indirect impact on the door die-casting was considered. By analyzing the structural design and material properties of the door, it was predicted that the impact in the lower left corner would cause the crack to extend further along the direction of stress concentration. Therefore, several additional second fault locations were identified on the potential crack propagation path. Finally, a three-dimensional model of the door die-casting was established, and all identified first and second fault locations were mapped into the model. Based on the distribution and morphology of these fault locations, adjacent fault locations were merged into two fault regions: one is the crack propagation region in the lower left corner, and the other is the impact damage region in the upper right corner. This example demonstrates the specific operational process and technical implementation of step S113 in practical applications. By marking the impact location, determining the first and second fault locations, and identifying the fault region based on the region mapping relationship, a more comprehensive understanding of the fault condition of the door die-casting can be obtained, providing strong support for subsequent management and repair.

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

[0052] In the specific implementation of this invention, the specific steps are as follows:

[0053] S121: Collect the model number of the door die casting, determine the 3D model of the door die casting in the factory state based on the model number of the door die casting and the die casting database, and mark multiple fault areas on the 3D model of the door die casting.

[0054] S122: Perform corresponding mechanical analysis on the location of multiple fault areas and output multiple mechanical distribution maps. 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 fault characteristics and the area of ​​the fault area.

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

[0056] In the embodiments of this application, the model number of the door die-casting is collected, and a three-dimensional model of the door die-casting in the factory state is determined based on the model number of the door die-casting and the die-casting database. Multiple fault areas are marked on the three-dimensional model of the door die-casting. This overall consideration of the model number of the door die-casting and the die-casting database ensures the accuracy of the three-dimensional model of the door die-casting in the factory state.

[0057] At this point, the model number of the door die-casting is collected, and a three-dimensional model of the door die-casting at the time of manufacture is obtained, including information such as geometric shape and material properties. Then, the record matching the collected model number is searched in the die-casting database. The database should contain three-dimensional model data of various models of door die-castings.

[0058] Accurately mark the fault areas identified in the previous steps (such as in step S113) on the 3D model for subsequent analysis. At this point, use 3D modeling software or a specialized marking tool to mark the location, size, and shape of the fault areas on the 3D model. Marking is achieved through color coding, highlighting, and adding annotations. Ensure that the marked fault areas match the actual situation to avoid omissions or mismarking. At the same time, the markings 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 point, 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 fault characteristics and the area of ​​the fault area, thus ensuring the accuracy of the mechanical analysis mode.

[0060] At this point, understanding the stress, strain, and other mechanical behaviors of the faulty area under stress provides a scientific basis for subsequent repair or improvement. Finite element analysis (FEA), computational fluid dynamics (CFD), or other mechanical simulation software are then used to perform mechanical analysis on the three-dimensional model marked with the faulty area. During the analysis, the actual working conditions of the die-cast door body, such as loads and boundary conditions, need to be considered.

[0061] The mechanical behavior of the fault area is displayed intuitively, facilitating analysis and understanding. Based on the mechanical analysis results, stress distribution maps, strain distribution maps, displacement distribution maps, and other mechanical distribution maps are generated. These maps use color coding, contour lines, and other methods to display the magnitude and distribution of mechanical parameters, ensuring that the output mechanical distribution maps are clear and readable, and that the colors and labels accurately reflect the changes in mechanical parameters.

[0062] Based on information such as the shape, size, and location of the fault area, identify the main characteristics of the fault, such as crack type, dent depth, and degree of deformation. Then, use visual inspection, measurement tools, or image processing software to conduct a detailed analysis of the fault area and extract its characteristics.

[0063] Based on 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, select the corresponding mechanical analysis method and parameter settings based on 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.). Ensure that the selected mechanical analysis mode matches the fault characteristics and area of ​​the region to avoid oversimplifying or complicating the analysis process.

[0064] Specifically, suppose a fault analysis is being performed on a die-cast automotive door. In step S113, three fault regions were identified: A (crack), B (dent), and C (deformation). Finite element analysis software was used to perform a mechanical analysis on the 3D model marked with the fault regions. The loads and boundary conditions of the die-cast door during actual operation were considered, such as the impact force of opening and closing the door and vibrations of the vehicle body. Based on the mechanical analysis results, stress distribution maps, strain distribution maps, and displacement distribution maps were generated. In the stress distribution map, stress concentration is observed in crack region A. In the strain distribution map, the strain in dent region B is relatively large. In the displacement distribution map, the displacement in deformation region C is significant.

[0065] Visual inspection and measurement tools determined that the crack type in crack region A was a penetrating crack with a length of approximately 5 mm; the depression depth in depression region B was approximately 2 mm; and the deformation degree in deformation region C was approximately 5%. For crack region A, a fracture mechanics analysis mode was selected, focusing on analyzing the crack propagation path and velocity. For depression region B, an elastoplastic mechanics analysis mode was selected to analyze the impact of the depression on stress concentration and plastic deformation of the surrounding material. For deformation region C, a structural mechanics analysis mode was selected to assess the impact of deformation on the overall stiffness and strength of the die-cast door body. The density and calculation accuracy of the analysis mesh were adjusted according to the size of the fault area to ensure the accuracy and efficiency of the analysis. Through these steps, a detailed mechanical analysis of the fault area of ​​the automotive door body die-casting was conducted, providing a scientific basis for subsequent repair or improvement.

[0066] Therefore, based on multiple mechanical distribution diagrams and a three-dimensional model of the door die-casting, the fault state diagram of the door die-casting is determined, the service life of the door die-casting is collected, and the fault level of the door die-casting is determined according to the fault state diagram, the service life of the door die-casting, and the mapping relationship between the fault state diagram, the service life of the door die-casting, and the fault level. This comprehensive approach, which incorporates the fault state diagram, the service life of the door die-casting, and the mapping relationship between the fault level, ensures the accuracy of the fault level of the door die-casting.

[0067] At this point, by integrating multiple mechanical analysis results, an intuitive fault state diagram is generated to display the fault distribution, severity, and potential impact of the door die-casting. Then, the mechanical distribution diagrams (such as stress distribution diagrams, strain distribution diagrams, and displacement distribution diagrams) are combined with the 3D model of the door die-casting, and the fault state diagram is generated through overlay, fusion, or color coding. The fault state diagram should clearly show the location, size, shape, and changes in mechanical parameters of the fault area. The accuracy and readability of the fault state diagram must be ensured to avoid information omissions or misleading information. Simultaneously, the interactions and influences between fault areas, as well as the impact of the fault on the overall performance of the door die-casting, are considered.

[0068] Collect the service life of the door die-casting parts and understand their usage history to provide a basis for assessing their remaining life and failure level; optionally, obtain their service life by reviewing the production, usage, or maintenance records of the door die-casting parts; for cases where the service life cannot be directly obtained, estimate it by interviewing users, conducting on-site surveys, or expert evaluations.

[0069] Based on the fault state diagram and service life, and combined with the fault level mapping relationship, the fault level of the door die-casting is quantitatively assessed. First, the severity and extent of the fault area are determined according to the fault state diagram. Then, the impact of the fault on the remaining service life of the door die-casting is assessed in conjunction with the service life. Finally, the fault level of the door die-casting is determined according to the fault level mapping relationship (such as a fault level classification standard based on factors such as fault characteristics, severity, and service life). The accuracy and applicability of the fault level mapping relationship are ensured, avoiding oversimplification or overcomplication of the assessment process. Simultaneously, the impact of the fault level on the safety performance and reliability of the door die-casting is considered.

[0070] Specifically, suppose a fault level assessment is being performed on a die-cast automotive door. In step S122, stress distribution maps, strain distribution maps, and displacement distribution maps have been generated for this die-cast part, and the fault characteristics of crack region A, dent region B, and deformation region C have been determined. The stress distribution maps, strain distribution maps, and displacement distribution maps are combined with the 3D model of the door die-cast part to generate a fault state map using color coding. In the fault state map, crack region A is displayed as a red highlighted area, indicating stress concentration and potential fracture risk; dent region B is displayed as a yellow area, indicating large strain and plastic deformation; and deformation region C is displayed as a blue area, indicating large displacement and a decrease in overall stiffness.

[0071] By reviewing the vehicle's production and maintenance records, it was determined that the die-cast door component had been in use for 5 years. Considering that the design life of automotive door die-castings is 10 years, this component has already reached half of its design life. Based on the fault condition diagram and service life, and in conjunction with the pre-established fault level mapping relationship, an assessment was conducted. Due to the severe stress concentration in crack area A, which is located in a critical stress-bearing part of the door die-casting, and considering its 5-year service life and potential fracture risk, the fault level of this die-casting was determined to be "severe." Although dented areas B and deformed areas C also exhibit some degree of fault, their impact on the overall performance of the door die-casting is smaller than that of crack area A. Considering the service life and design life, the fault level of these two areas was determined to be "moderate."

[0072] In one embodiment of this application, a fault level mapping table is collected, as 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 dent serious <10 generally dent Mild / Mild >10 slight Deformation serious <5 serious Deformation Mild / Mild ≥5 generally

[0075] refer to Figure 4 In step S13, a fault management event is determined based on the fault level and morphology of the door die casting. The fault management event represents the maintenance status of different stages in multiple fault areas.

[0076] In the specific implementation of this invention, the specific steps are as follows:

[0077] S131: Collect the fault level of the door die casting and determine the sub-fault level of multiple fault areas based on the classification of the fault level of the door die casting.

[0078] S132: Determine the first fault state of multiple fault areas based on the sub-fault levels and corresponding area areas of multiple fault areas, and determine the second fault state of multiple fault areas based on the sub-fault levels of multiple fault areas and the shape of the door die-casting.

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

[0080] In the embodiments of this application, the fault level of the door 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 die-casting, thus ensuring the accuracy of the sub-fault levels of multiple fault areas.

[0081] At this point, the fault level of the door die-casting is collected to obtain the current overall fault level of the door die-casting, which is the basis for determining the sub-fault levels. Optionally, through the previous evaluation steps (such as S123), the fault state diagram, service life and fault level mapping relationship of the door die-casting have been obtained. Based on this information, the overall fault level of the door die-casting is determined.

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

[0083] Specifically, suppose there is a die-cast door body. After the previous evaluation steps (such as S123), the overall failure level of the die-cast door body is "moderate". Now, it is necessary to further determine the sub-failure level of each failure area; Overall failure level: moderate; Failure area 1: crack area; Failure type: crack; Severity: long and deep, affecting the overall strength and stability of the door body; Impact on overall performance: significant, causing the door body to be unusable or posing a safety hazard; Sub-failure level: severe (because the severity of the crack is high, the impact on overall performance is also significant).

[0084] Fault Area 2: Deformation Area; Fault Type: Deformation; Severity: Minor, only affecting the appearance and local rigidity of the door; Impact on Overall Performance: Minor, does not affect the normal use of the door; Sub-Fault Level: General (because the severity of the deformation is low, the impact on overall performance is also minor)

[0085] Fault Area 3: Wear Area; Fault Type: Wear; Severity: Moderate, with a large wear area but shallow depth; Impact on Overall Performance: Moderate, affecting the service life and appearance of the door; Sub-Fault Level: Slight to Moderate (because although the wear area is large, the depth is shallow, and the impact on overall performance is between moderate and slight, it is judged as slight to moderate at the discretion of the authorities); Through this process, 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 state of multiple fault areas is determined based on the sub-fault levels and corresponding area areas of multiple fault areas, and the second fault state of multiple fault areas is determined based on the sub-fault levels of multiple fault areas and the shape of the door die-casting; this overall consideration of the sub-fault levels of multiple fault areas and the shape of the door die-casting ensures the accuracy of the second fault state of multiple fault areas.

[0087] At this point, the first fault state of multiple fault regions is determined based on their sub-fault levels and corresponding area. Taking into account both the sub-fault levels and area, the degree of impact on the overall performance of the die-cast door body is determined, i.e., the first fault state. Optionally, for each fault region, its sub-fault level is first considered, which is the basis for assessing the severity of the fault. Next, the area of ​​the fault region is considered; a larger area means a greater impact on overall performance. Combining the sub-fault levels and area, an evaluation standard or formula is developed to quantify the first fault state of each fault region. For example, different weights are assigned to the sub-fault levels and areas, and then a weighted sum or product is calculated. Based on the evaluation results, the first fault state of each fault region is classified into levels such as "high risk," "medium risk," or "low risk."

[0088] The second fault state of multiple fault areas is determined based on the sub-fault levels and the morphology of the door die-casting. In addition to considering the sub-fault levels and area of ​​the fault area, the morphology of the door die-casting (such as shape, structure, and critical parts) is also taken into account to further assess the impact of the fault on the door's function and appearance, i.e., the second fault state. Optionally, for each fault area, its sub-fault level is first referenced as a basic assessment. Then, the morphological factors of the door die-casting are considered, especially whether the fault area is located in a critical part (such as stress points, connections, and sealing surfaces), and whether the fault affects the overall structure or appearance of the door. A comprehensive analysis is conducted, combining the sub-fault levels and morphological factors, to determine the second fault state of each fault area. This requires professional knowledge and experience to judge. Based on the assessment results, the second fault state of each fault area is also classified into different levels.

[0089] Specifically, suppose there is a die-cast door body. The previous steps have already determined the sub-fault levels of multiple fault areas. Now, it is necessary to further determine the first and second fault states of these fault areas. Determining the first fault state: Fault area A: Sub-fault level is "Severe," area is 10 square centimeters; considering the large area and severe sub-fault level, its first fault state is assessed as "High Risk"; Fault area B: Sub-fault level is "Moderate," area is 5 square centimeters; although the area is not small, the sub-fault level is moderate, so its first fault state is assessed as "Medium Risk"; Fault area C: Sub-fault level is "Minor," area is 2 square centimeters; the area is small and the sub-fault level is minor, so its first fault state is assessed as "Low Risk."

[0090] Determine the second fault status: Fault Area A: Located at the stress point of the door, and the sub-fault level is "Severe"; since the stress point is crucial to the overall strength and stability of the door, and the fault is severe, its second fault status is also assessed as "High Risk"; Fault Area B: Although located in a non-critical part of the door, the sub-fault level is "Moderate," and the area is large, affecting the local performance of the door; considering all factors, its second fault status is assessed as "Medium Risk" (or, depending on the specific circumstances, if the morphological factors are not decisive, it is also maintained as "Medium Risk," but it is emphasized that attention is needed); Fault Area C: Located at the edge of the door, not affecting the overall structure and appearance, and the sub-fault level is "Minor"; its second fault status is assessed as "Low Risk"; Through these steps, a specific first and second fault status is determined for each fault area, providing a more comprehensive basis for subsequent management and maintenance. This status information helps decision-makers better understand the degree of impact of the fault, thereby formulating reasonable maintenance plans and resource allocation.

[0091] Therefore, in each fault zone, corresponding sub-fault management events are determined based on the first fault state, the second fault state, and the event mapping relationship. Fault management events are 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 zones, presenting corresponding maintenance situations. This approach takes into account 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. At the same time, it also takes into account the overall consideration of the fault level and the shape of the door die-casting, ensuring the accuracy of the fault management events.

[0092] At this point, based on the first fault state, the second fault state, and the event mapping relationship, the corresponding sub-fault management events are determined. Then, according to the first fault state, the second fault state, and the predefined event mapping relationship for each fault area, specific sub-fault management events are determined. These events represent maintenance, inspection, or other management measures that need to be taken for each fault area. Optionally, the event mapping relationship is a predefined set of rules or a decision tree that associates specific fault states with corresponding management events. For each fault area, its corresponding management event in the event mapping relationship is found. This requires considering the combination of the first and second fault states, as well as any relevant contextual information (such as the door's usage environment, historical maintenance records, etc.). Sub-fault management events for each fault area are determined; these events are maintenance tasks, inspection plans, monitoring activities, or other necessary management measures.

[0093] Fault management events are determined by synthesizing multiple sub-fault management events. These sub-fault management events from multiple fault areas are integrated into a single overall fault management event for unified management and planning. At this stage, the priority, urgency, and interdependencies 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. A single overall fault management event is then synthesized, containing detailed information about all sub-fault management events, such as task description, responsible person, execution time, and required resources.

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

[0095] Table 2 Sub-Fault Management Event Matching Table

[0096]

[0097] Specifically, suppose there is a die-cast door body, 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 arranging a professional team to conduct a detailed inspection and formulate a maintenance plan".

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

[0099] In the specific implementation of this invention, the specific steps are as follows:

[0100] S141: Collect maintenance nodes for multiple fault areas, and determine the maintenance progress of multiple fault areas based on the maintenance nodes of multiple fault areas and the corresponding online maintenance images;

[0101] S142: Determine the overall maintenance progress of the door die casting based on the maintenance progress of multiple fault areas, the corresponding real-time images, and the real-time morphology of the door die casting. At this time, the overall maintenance progress of the door die casting presents the overall maintenance progress of the door die casting at the current time.

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

[0103] In the embodiments of this application, maintenance nodes of multiple fault areas are collected, and the maintenance progress of multiple fault areas is determined based on the maintenance nodes of multiple fault areas and the corresponding online maintenance images; the overall consideration of multiple fault areas maintenance nodes and corresponding online maintenance images is taken into account to ensure the accuracy of the maintenance progress of multiple fault areas.

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

[0105] By combining maintenance node information and online maintenance images, the maintenance progress of each fault area is accurately assessed. At this point, real-time or recent maintenance images acquired by the online monitoring system are compared with the maintenance node information to determine the actual completion status of the current maintenance work. Based on information such as work progress, personnel allocation, and equipment status in the images, combined with the timestamps of the maintenance nodes, the maintenance progress of each fault area is comprehensively evaluated. Maintenance progress is expressed using percentages, stage divisions, or other quantitative indicators. The clarity and timeliness of the online maintenance images are ensured to accurately reflect the actual status of the maintenance work. Simultaneously, various factors affecting progress, such as weather and material supply, should be considered during the evaluation process.

[0106] Specifically, suppose there is a door die-casting maintenance project with three fault areas, namely fault areas A, B, and C; Fault area A: maintenance starts at 8:00 AM, critical operations (such as welding repair) are completed at 10:00 AM, and the phased inspection is scheduled for 11:00 AM; Fault area B: maintenance starts at 9:00 AM, and surface grinding is currently underway, which is expected to be completed at 1:00 PM; Fault area C: due to material shortage, maintenance work has not yet started, but it is expected to begin at 2:00 PM after the materials arrive.

[0107] Fault Area A: Online monitoring images show that welding repair work has been completed and phased inspections are underway. Based on maintenance node information, the maintenance progress of Fault Area A is estimated to be approximately 70% (assuming welding repair accounts for the majority of the overall maintenance work). Fault Area B: Online monitoring images show that surface grinding is in progress but not yet completed. Based on maintenance node information and the work progress in the images, the maintenance progress of Fault Area B is estimated to be approximately 30% (assuming surface grinding is an important step in the overall maintenance work). Fault Area C: Due to material shortages, maintenance work has not yet started; therefore, the maintenance progress of Fault Area C is 0%. In summary, by collecting maintenance node information and using online maintenance images for progress assessment, the maintenance progress of each fault area is determined, and subsequent work plans and resource allocation strategies are formulated accordingly.

[0108] Furthermore, the overall maintenance progress of the door 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 die-casting. At this point, the overall maintenance progress of the door die-casting reflects the overall maintenance progress of the door die-casting at the current time. This comprehensive consideration of the maintenance progress of multiple fault areas, the corresponding real-time images, and the real-time morphology of the door die-casting ensures the accuracy of the overall maintenance progress of the door die-casting.

[0109] At this point, the maintenance progress of each fault area is summarized to obtain an overview of the overall maintenance progress of the door die-casting. The latest maintenance progress data for each fault area is collected, expressed as a percentage, completion stage, or specific task completion status. Based on the importance and scale of each fault area (e.g., area, impact on overall performance), appropriate weights are assigned (if applicable). The maintenance progress of each fault area is summarized, and a weighted average or comprehensive score of the overall maintenance progress is calculated based on the assigned weights.

[0110] By observing real-time images and the real-time morphology of the door die-castings, the assessment results of the overall maintenance progress are further verified and refined. At this point, real-time image resources such as photos and videos taken on-site, such as online monitoring systems, are used to observe the overall appearance of the door 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 assess the current actual maintenance level of the door die-castings. The morphological changes of the door die-castings during the maintenance process (such as color, shape, size, etc.) and the impact of these changes on overall performance and safety are considered. The overall maintenance progress is corrected and adjusted by combining the real-time image assessment results with the previous maintenance progress summary data.

[0111] Present the overall maintenance progress of the door die-casting components in a clear and accurate manner at the current time. At this point, based on the summary and evaluation results, determine the overall maintenance progress of the door die-casting components (expressed in the form of percentage, stage division, color coding, etc.); create 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 the reports or updates so that relevant personnel can understand the maintenance progress in a timely manner and make corresponding decisions.

[0112] Specifically, suppose there is a door die-casting maintenance project with three fault areas (A, B, and C); Fault area A: 70% of the maintenance work has been completed, including welding repair and preliminary grinding; Fault area B: 50% of the maintenance work has been completed, and surface treatment and rust prevention are underway; Fault area C: Due to material shortages, only 10% of the preparatory work has been completed, and actual maintenance has not yet begun; Assuming that each fault area has the same weight (i.e., 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 underway, but the rust prevention treatment seemed uneven 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 it was expected to begin in the afternoon; based on these observations, the overall maintenance schedule was revised: considering that some details of the work in fault areas A and B were not yet completed, the overall maintenance schedule 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 prepared, which outlined the overall maintenance progress of the door die-cast parts at 40%, and detailed the maintenance progress, existing problems and challenges (such as rough grinding, uneven rust prevention, etc.) of each fault area. The report also included follow-up work plans, including strengthening the detailed work of fault areas A and B, and ensuring that the maintenance work of fault area C starts as planned. The report was sent to relevant personnel via email so that they could be informed of the maintenance progress in a timely manner and make corresponding decisions.

[0115] Therefore, by collecting the preset maintenance time target, determining the remaining maintenance progress based on the overall maintenance progress of the door die-casting, determining 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 target, and triggering the autonomous adjustment of the maintenance progress of multiple fault areas based on the accelerated maintenance events of multiple fault areas, it takes into account the overall consideration of the remaining maintenance progress, the maintenance progress of multiple fault areas, and the preset maintenance time target, ensuring the accuracy of accelerated maintenance events for multiple fault areas.

[0116] At this point, a preset maintenance time target is collected to clarify the expected completion time of the door die-casting maintenance project, serving as a reference benchmark for subsequent progress control and accelerating maintenance events; optionally, a preset maintenance time target is obtained from the project plan or contract, which is expressed in the form of a specific date, time period, or working duration; ensure that the collected maintenance time target is accurate, reliable, and approved 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 point, the previously determined overall maintenance progress data of the door die-casting parts (such as percentage, stage division, etc.) are used. Based on the preset maintenance time target and the current time, the remaining available maintenance time is calculated. Combining the remaining available maintenance time and the current overall maintenance progress, the remaining maintenance workload and time distribution to be completed are evaluated.

[0118] Identify and determine which fault areas require accelerated 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 behind schedule or have potential delay risks; based on the actual situation of these areas and preset maintenance time targets, formulate specific measures and plans to accelerate maintenance events; accelerated maintenance events include increasing manpower, allocating resources, adjusting work plans, and adopting more efficient technologies or methods, etc.

[0119] By implementing expedited maintenance events, the maintenance progress of each fault area can be autonomously controlled to ensure that the overall maintenance project can be completed on time. At this time, the specific measures and plans for expedited maintenance events are communicated to the relevant maintenance teams and personnel. The implementation of expedited maintenance events is monitored to ensure that all measures are effectively implemented. Based on the actual situation and feedback during the implementation process, the strategies and plans for expedited maintenance events are adjusted in a timely manner. Through continuous progress monitoring and control, the maintenance progress of each fault area is ensured to gradually approach the preset maintenance time target.

[0120] Specifically, suppose there is a maintenance project for a door die-cast component containing three fault areas (A, B, and C), with a preset maintenance time target of two weeks. The preset maintenance time target obtained from the project plan is two weeks (i.e., 14 days). Assume the current time is the seventh day after the project started. Based on the previous progress assessment, the overall maintenance progress is 40% (let's say it's expressed as a 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, the remaining maintenance workload is assessed to be 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 maintenance work completed; Fault area B: 30% of maintenance work completed; Fault area C: Due to material shortage, only 10% of preparation work has been completed; Identify the fault areas that are lagging behind in progress as B and C; Develop specific measures and plans to expedite the maintenance event: Increase manpower for fault area B and allocate more efficient grinding equipment; Prioritize resolving the material shortage problem in fault area C and arrange additional maintenance teams for support.

[0122] Communicate the specific measures and plans for expediting maintenance events to the relevant maintenance teams and personnel; monitor the implementation of expedited maintenance events to ensure that all measures are effectively implemented; for example, regularly check the grinding progress of fault area B and the material availability of fault area C; adjust the strategies and plans for expediting maintenance events in a timely manner based on the actual situation and feedback during implementation; 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 control, 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 of the remaining time, it is found that the overall maintenance progress has increased to 70%, and the progress of each fault area has accelerated, meeting the expected target.

[0123] In one embodiment of this application, the preset maintenance time target is: to be completed within 15 days; the weight allocation (based on the importance and scale of the fault area) is: 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 weights and remaining score):

[0126] Fault Area B: High weight but low score, requires accelerated progress; Measures: Same as above, increase manpower and optimize processes; Fault Area C: High weight with room for improvement, also requires accelerated progress; Measures: Same as above, allocate tools and work overtime; Fault Area A: High weight but good progress, can maintain the original progress; By implementing acceleration measures, the progress of fault areas B and C was significantly improved, and the overall project was successfully completed within 15 days.

[0127] refer to Figure 6 In step S15, if multiple door die-casting parts are under synchronous maintenance, the usage sequence of the multiple door die-casting parts is collected, and the current configuration of maintenance personnel is optimized based on the usage sequence of the multiple door die-casting parts and the overall maintenance progress of the multiple door die-casting parts.

[0128] In the specific implementation of this invention, the specific steps are as follows:

[0129] S151: Within the same maintenance space, collect data on multiple door die-casting parts that are in the same maintenance space, with multiple door die-casting parts being maintained synchronously, and collect the work content of each maintenance personnel in the maintenance space.

[0130] S152: Determine the arrival sequence of multiple door die castings based on the traceability of multiple door die castings, and determine the usage sequence of multiple door die castings according to the arrival sequence and corresponding model.

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

[0132] In the embodiments of this application, multiple door die-cast parts located in the same maintenance space are collected, and the multiple door die-cast parts are in a synchronous maintenance state. The work content of each maintenance personnel in the maintenance space is also collected.

[0133] At this point, identify and record all door die-castings that require maintenance within the same maintenance space to ensure no one is missed. Then, use barcode or RFID technology to scan the unique identifier on each door die-casting and record its model, serial number, and other key information. Alternatively, maintenance personnel can manually check and record the information of each door die-casting. Ensure that the recorded information is accurate and corresponds one-to-one with the door die-castings in the actual maintenance space.

[0134] Ensure that all collected door 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 die-casting to confirm that they are all in the maintenance process. Communicate with maintenance personnel to understand their maintenance plans and schedules to ensure that the maintenance work of all door die-castings is carried out synchronously. If a door die-casting is found to be out of maintenance, the cause should be identified in a timely manner and measures should be taken to bring it into the maintenance process.

[0135] Understand and record the specific work content and responsibilities of each maintenance personnel within the current maintenance area to facilitate personnel allocation and efficiency analysis. At this time, record information such as the door die-casting parts under each maintenance personnel's responsibility, maintenance tasks, required tools and materials, etc., through work logs, task assignment sheets, or electronic management systems. Communicate face-to-face with maintenance personnel to confirm their work content and progress, as well as any 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, suppose there is a large door die-casting maintenance workshop containing multiple door die-castings of different models and degrees of damage. Now, information collection and status confirmation need to be carried out according to the steps in S151. Use an RFID scanner to scan the RFID tag on each door die-casting one by one, and record their model (e.g., XYZ-1234), serial number (e.g., ABC123456), and current location (e.g., maintenance area A). After scanning, an electronic list containing information on all door die-castings is obtained to ensure that no one is missed.

[0137] A review of the maintenance records for each door die-cast component revealed that maintenance had commenced within the past week and was expected to be completed within the next two weeks. Communication with the maintenance personnel confirmed that they were working according to the scheduled maintenance plan and timetable without any delays or disruptions. Therefore, it was confirmed that all door die-cast components were undergoing synchronized maintenance.

[0138] By reviewing the work assignments of each maintenance worker through the electronic management system, it was found that they were responsible for specific maintenance work on different models of die-cast door parts, such as welding, grinding, and spraying.

[0139] We communicated face-to-face with maintenance personnel to understand their work progress, required tools and materials, and difficulties encountered (such as a shortage of a certain type of part). Based on this information, we analyzed the work efficiency of the maintenance personnel and identified a potential bottleneck: the shortage of a certain part was hindering the work progress of one maintenance personnel. We decided to immediately contact the supplier to replenish the part to ensure that the maintenance work could proceed smoothly. Through the steps in S151, we successfully collected information and status of multiple door die-cast parts in the same maintenance space and understood the work content and progress of the maintenance personnel. This information provided an important basis for subsequent personnel allocation, resource optimization, and progress tracking.

[0140] Furthermore, the arrival sequence of multiple door die-castings is determined based on the traceability of multiple door die-castings, and the usage sequence of multiple door die-castings is determined according to the arrival sequence and corresponding model of multiple door die-castings; the overall consideration of the arrival sequence and corresponding model of multiple door die-castings is taken into account, ensuring the accuracy of the usage sequence of multiple door die-castings.

[0141] At this point, by tracing the entry records or related documents of each door die-casting component, the order in which they entered the maintenance area is determined. Then, the entry record sheet or electronic database of the door die-casting components is consulted to record the entry date and time of each door die-casting component. Based on the entry date and time, all door die-casting components are sorted to determine their entry order. If the entry records are incomplete or missing, supplementary information is obtained by consulting relevant maintenance personnel or management personnel.

[0142] Based on the arrival sequence and specific models of the die-cast door components, a usage sequence that meets maintenance needs and usage priorities is developed. At this point, the model, damage level, and urgent customer needs of each die-cast door component are analyzed to assess its maintenance priority. Based on the arrival sequence and assessment results, a preliminary usage sequence plan is developed. The feasibility and sufficiency of the usage sequence plan are confirmed through communication with the customer, maintenance team, and relevant stakeholders. Based on feedback, the usage sequence plan is adjusted and optimized as necessary.

[0143] Specifically, suppose there is a maintenance workshop containing multiple door die-casting parts of different models. These door die-casting parts have already undergone information collection and status confirmation according to step S151. Now, it is necessary to determine their arrival order and usage order according to step S152. The arrival record table of the door die-casting parts is consulted, and it is found that the earliest arrival was the XYZ-1234 model door die-casting part, with an arrival date of the 10th of last month; followed by the ABC123456 model, with an arrival date of the 15th of last month; and so on, recording the arrival dates of all door die-casting parts. Based on the arrival dates, all door die-casting parts are sorted, and their arrival order is determined as follows: XYZ-1234, ABC123456, ... (other models are sorted by arrival date).

[0144] An analysis of the model and damage extent of each door die-casting component revealed that the XYZ-1234 model had minor damage and the customer's urgent need for it was not high; while the ABC123456 model had severe damage and the customer urgently needed it. Based on the arrival sequence and assessment results, a preliminary usage sequence plan was developed: first, maintain the ABC123456 model due to its severe damage and urgent customer need; second, maintain the XYZ-1234 model, which, although less damaged, still required timely maintenance; finally, maintain the other models in the order of arrival. Communication with the customer and maintenance team confirmed the feasibility and suitability of the usage sequence plan. The customer expressed great satisfaction with the urgent maintenance need for the ABC123456 model and also approved the maintenance plan for the other door die-casting components. Based on customer feedback, the usage sequence plan was slightly adjusted to ensure that each door die-casting component could be maintained before the customer's required timeframe.

[0145] Therefore, the overall maintenance progress of multiple door die-castings is ordered sequentially according to this usage order. If the overall maintenance progress of the previous door die-casting is lower than that of the next door die-casting, the personnel optimization of the maintenance personnel for the next door die-casting is triggered based on the overall maintenance progress of the previous door die-casting, the remaining maintenance tasks of the previous door die-casting, and the personnel configuration of the next door die-casting. This allows for the autonomous control of the maintenance progress of multiple fault areas and the optimization of the current personnel configuration, ensuring the accuracy of fault management for door die-castings.

[0146] At this point, based on the previously determined usage sequence, track and record the overall progress of each door die-casting component during the maintenance process to ensure they proceed in an orderly manner according to the predetermined plan. Optionally, establish a progress tracking system, such as a spreadsheet or project management software, to record the current maintenance status of each door die-casting component (e.g., completed tasks, remaining tasks, estimated completion time, etc.). Regularly check (e.g., daily or weekly) and update the progress tracking system to ensure the accuracy and timeliness of the information. Sort the door die-casting components in the progress tracking system according to the usage sequence to quickly identify which door die-casting components are lagging behind schedule.

[0147] Identify delayed door die castings so that timely intervention measures can be taken; optionally, compare the records of adjacent door die castings in the progress tracking system, paying particular attention to their expected completion time and the percentage of completed tasks; if the expected completion time of the previous door die casting is later than that of the next, or if its percentage of completed tasks is lower than that of the next, then the previous door die casting is considered to be delayed.

[0148] By adjusting the maintenance personnel allocation, the maintenance process of the delayed door die-casting parts is accelerated, ensuring the smooth execution of the overall maintenance plan. At this point, the reasons for the delay of the previous door die-casting part are analyzed, such as high task complexity, insufficient maintenance personnel skills, or material shortages. The adequacy of the maintenance personnel allocation for the next door die-casting part is assessed, along with whether there is room for personnel redeployment. Based on the assessment results, a personnel optimization plan is developed, such as transferring some personnel from the maintenance team of the next door die-casting part to the maintenance work of the previous door die-casting part, or adding additional maintenance personnel to the maintenance team of the previous door die-casting part. The personnel optimization plan is communicated and explained to the maintenance personnel to ensure their understanding and support. The personnel optimization plan is implemented, and its effectiveness is continuously tracked and evaluated.

[0149] Specifically, suppose there are three die-cast door components, A, B, and C, which are maintained in the order of use. An electronic spreadsheet is set up as a progress tracking system to record the current maintenance status of the three die-cast door components A, B, and C. After a week of maintenance work, it is found that the progress of die-cast door component A is lagging behind, and the expected completion time has been postponed from the original Tuesday to the Thursday of next week; while the progress of die-cast door components B and C is proceeding as planned.

[0150] Comparing the progress records of the three die-cast parts A, B, and C, it was found that the progress of die-cast part A was indeed lower than that of B and C. The reason for the delay in the progress of die-cast part A was analyzed and found to be that the time taken for a certain complex task exceeded expectations. The maintenance personnel configuration of die-cast parts B and C was evaluated and it was found that some members of the maintenance team for die-cast part B were performing relatively simple tasks, which were expected to be completed in the next few days.

[0151] Therefore, a personnel optimization plan was developed: two experienced maintenance personnel were transferred from the maintenance team of the B-body die-casting to the maintenance work of the A-body die-casting to accelerate its progress; the importance and urgency of the plan were explained to the maintenance personnel, who expressed their understanding and support; the personnel optimization plan was implemented, and the maintenance progress of the A-body die-casting was continuously tracked and evaluated; after the adjustment, the progress of the A-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 die-casting was successfully identified and resolved, ensuring the smooth execution of the overall maintenance plan.

[0152] In one embodiment of this application, it is assumed that there are three door die-cast parts A, B, and C, which are maintained according to a predetermined usage order; 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 die casting A (60%) is lower than that of its subsequent door die casting B (80%). Meanwhile, considering that the remaining task complexity of A is 3 (medium) and that B has a relatively sufficient staff (4 people), it is considered to transfer some personnel from the maintenance team of B to the maintenance work of A.

[0156] Personnel optimization strategy: Transfer 1 person from the 4-person maintenance team for the B-body die casting to the maintenance work of the A-body die casting; Adjusted configuration: 1 additional person is added for the A-body die casting, for a total of X+1 people (X is the original number of people); The B-body die casting team is reduced to 3 people, but it can still meet its maintenance needs.

[0157] Please see Figure 7 , Figure 7 This is a schematic diagram of the structural composition of the fault management system for the die-cast door body in an embodiment of the present invention; the fault management system for the die-cast door body includes:

[0158] Fault area module 21 is used to determine multiple fault areas based on the recognition of the current image of the door die-casting;

[0159] Fault level module 22 is used to determine the fault state diagram of the door die casting based on the mechanical analysis of multiple fault areas, and to determine the fault level of the door die casting based on the fault state diagram and the service life of the door die casting.

[0160] The fault management module 23 is used to determine fault management events based on the fault level and morphology of the door die casting. These fault management events represent the maintenance status of different stages in multiple fault areas.

[0161] The maintenance progress module 24 is used to determine the overall maintenance progress of the door die-casting part based on the maintenance progress of multiple fault areas in the fault management event, and to trigger the autonomous adjustment of the maintenance progress of multiple fault areas based on the overall maintenance progress of the door die-casting part and the preset maintenance time target.

[0162] The optimization module 25 is used to collect the usage order of multiple door die-castings if multiple door die-castings are under synchronous maintenance, and optimize the current maintenance personnel configuration based on the usage order of multiple door die-castings and the overall maintenance progress of multiple door die-castings.

[0163] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity, 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 die-cast door components, characterized in that, include: Multiple fault areas are identified based on the recognition of the current image of the door die-casting, including: moving the door die-casting to the imaging area after damage, taking a circular image of the door die-casting to acquire the current image of the door die-casting; identifying multiple surface abnormal areas based on the detection of the current image of the door die-casting, and determining the overall abnormal area based on the multiple surface abnormal areas and the surface morphology of the door die-casting; marking multiple impact positions on the door die-casting after damage, determining multiple first fault positions based on the multiple impact positions and the overall abnormal area, determining multiple second fault positions based on the multiple impact positions and the surface morphology of the door die-casting, and determining multiple fault areas based on the multiple first fault positions, the multiple second fault positions, and the area mapping relationship. The failure state diagram of the door die-casting is determined based on the mechanical analysis of multiple failure areas. The failure level of the door die-casting is then determined based on the failure state diagram and the service life of the door die-casting. This process includes: collecting the model number of the door die-casting; determining a 3D model of the door die-casting in its factory state based on the model number and a die-casting database; marking multiple failure areas on the 3D model of the door die-casting; performing corresponding mechanical analysis on the locations of the multiple failure areas, outputting multiple mechanical distribution diagrams; identifying failure characteristics based on the identification of multiple failure areas; determining the mechanical analysis mode based on the type of failure characteristic and the area of ​​the failure region; determining the failure state diagram of the door die-casting based on the multiple mechanical distribution diagrams and the 3D model of the door die-casting; collecting the service life of the door die-casting; and determining the failure level of the door die-casting based on the mapping relationship between the failure state diagram, the service life of the door die-casting, and the failure level. Fault management events are determined based on the fault level and morphology of the door die casting. These fault management events represent maintenance status at different stages of multiple fault areas. In fault management events, the overall maintenance progress of the door die-casting is determined based on the maintenance progress of multiple fault areas, and the autonomous adjustment of the maintenance progress of multiple fault areas is triggered based on the overall maintenance progress of the door die-casting and the preset maintenance time target. If multiple door die-cast parts are under simultaneous maintenance, the usage sequence of the multiple door die-cast parts is collected, and the current maintenance personnel configuration is optimized based on the usage sequence of the multiple door die-cast parts and the overall maintenance progress of the multiple door die-cast parts.

2. The fault management method for door die-cast parts according to claim 1, characterized in that, The fault management event is determined based on the fault level and morphology of the door die-casting. This fault management event represents the maintenance status at different stages of multiple fault areas, including: Collect the fault levels of the door die-cast parts, and determine the sub-fault levels of multiple fault areas based on the classification of the fault levels of the door die-cast parts; The first fault state of multiple fault regions is determined based on the sub-fault levels and corresponding area of ​​multiple fault regions, and the second fault state of multiple fault regions is determined based on the sub-fault levels of multiple fault regions and the shape of the door die-casting.

3. The fault management method for door die-cast parts according to claim 2, characterized in that, Based on door die casting The fault level and the morphology of the die-cast door body determine the fault management event, which represents the maintenance status at different stages of multiple fault areas, and also includes: In each fault zone, the corresponding sub-fault management event is determined based on the first fault state, the second fault state, and the event mapping relationship. The fault management event is determined by the synthesis of multiple sub-fault management events. At this time, the multiple sub-fault management events are distributed in different stages of multiple fault zones, presenting the corresponding maintenance status.

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

5. The fault management method for door die-cast parts according to claim 4, characterized in that, In the fault management event, the overall maintenance progress of the door die-casting is determined based on the maintenance progress of multiple fault areas. The autonomous adjustment of the maintenance progress of multiple fault areas is triggered based on the overall maintenance progress of the door die-casting and a preset maintenance time target. This also includes: The overall maintenance progress of the door 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 die-casting. At this time, the overall maintenance progress of the door die-casting presents the overall maintenance progress of the door die-casting at the current time. The system collects preset maintenance time targets, determines the remaining maintenance progress based on the overall maintenance progress of the door die-casting, determines 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 triggers autonomous adjustment of the maintenance progress of multiple fault areas based on the accelerated maintenance events of multiple fault areas.

6. The fault management method for door die-cast parts according to claim 1, characterized in that, If multiple door die-castings are under simultaneous maintenance, the usage sequence of the multiple door die-castings is collected, and the current maintenance personnel configuration is optimized based on the usage sequence and the overall maintenance progress of the multiple door die-castings, including: Within the same maintenance space, multiple door die-cast parts located in the same maintenance space are collected. These multiple door die-cast parts are under synchronous maintenance. The work content of each maintenance personnel in this maintenance space is also collected. The arrival sequence of multiple door die-castings is determined by tracing the multiple door die-castings, and the usage sequence of the multiple door die-castings is determined according to the arrival sequence and corresponding model of the multiple door die-castings.

7. The fault management method for door die-cast parts according to claim 6, characterized in that, If multiple door die-castings are under simultaneous maintenance, the usage sequence of the multiple door die-castings is collected, and the current maintenance personnel configuration is optimized based on the usage sequence and the overall maintenance progress of the multiple door die-castings. This also includes: The overall maintenance progress of multiple door die-casting parts is ordered in sequence according to the usage order. If the overall maintenance progress of the previous door die-casting part is lower than that of the next door die-casting part, the personnel optimization of the maintenance personnel of the next door die-casting part is triggered based on the overall maintenance progress of the previous door die-casting part, the remaining maintenance tasks of the previous door die-casting part, and the maintenance personnel configuration of the next door die-casting part.

8. A fault management system for die-cast door components, characterized in that, The fault management system for the door die-casting component is applied to the fault management method for the door die-casting component as described in any one of claims 1-7, and the fault management system for the door die-casting component includes: The fault area module is used to identify multiple fault areas based on the recognition of the current image of the door die-casting part; The fault level module is used to determine the fault state diagram of the door die-casting part based on the mechanical analysis of multiple fault areas. The failure level of the door die-casting is determined based on the failure status diagram and the service life of the door die-casting. The fault management module is used to determine fault management events based on the fault level and shape of the door die casting. These fault management events represent the maintenance status of different stages in multiple fault areas. The maintenance progress module is used to determine the overall maintenance progress of the door die-casting part based on the maintenance progress of multiple fault areas in the fault management event, and to trigger the autonomous adjustment of the maintenance progress of multiple fault areas based on the overall maintenance progress of the door die-casting part and the preset maintenance time target. The optimization module is used to collect the usage sequence of multiple door die-castings if they are under synchronous maintenance, and optimize the current maintenance personnel configuration based on the usage sequence and the overall maintenance progress of the multiple door die-castings.

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