Fault omen diagnosis system and fault omen diagnosis method

Abstract

Provided are a fault omen diagnosis system and a fault omen diagnosis method for reducing collected measurement data, identifying a component in which an abnormality has occurred, and diagnosing a fault omen of a target member comprising a plurality of components. A fault sign diagnosis system (1) is provided with a fault sign recognition unit (13) that recognizes a fault sign of a component of a movable unit (160). The failure omen recognition unit (13) executes a first monitoring process in which the acoustic emission measurement process is repeatedly executed and whether or not a first determination condition in which the number of times the acoustic emission waves are detected is equal to or greater than a predetermined number of determination times is satisfied, and when the first determination condition is satisfied, the failure omen recognition unit (13) ends the first monitoring process and executes a second monitoring process in which the failure omen recognition unit (13) executes a failure omen recognition process in which the failure omen recognition unit (13) stops the failure omen recognition process. And an identification unit that repeatedly executes a vibration measurement process in which the vibration detection information is acquired by the vibration detection information acquisition unit and the vibration level of the component is identified on the basis of the vibration detection information, and identifies a fault omen of the component on the basis of the degree of increase in the vibration level of the component.

Description

Technical Field

[0001] The invention relates to a fault omen diagnosis system and a fault omen diagnosis method. Background Art

[0002] Conventionally, a diagnostic device has been proposed that determines abnormality in an engine component based on the maximum amplitude value of a sound wave signal detected from acoustic emission waves generated by the engine component during engine operation (see, for example, Patent Document 1).

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent No. 6373012 Summary of the Invention

[0006] Problems to be solved by the invention

[0007] When measuring acoustic emissions to diagnose an abnormality in a target component, as in the diagnostic device described in the background art, there is a drawback: when the target component consists of multiple components, such as in an electric power transmission unit mounted on a vehicle, it is difficult to pinpoint the component experiencing the abnormality. Therefore, vibration measurement can be used to pinpoint the abnormal component among the multiple components. However, this approach has the drawback of using vibration changes from the initial use of the target component to determine the component abnormality, requiring a large-scale data processing system capable of collecting and storing vibration measurement data.

[0008] The present invention is completed in view of the above situation, and its purpose is to provide a fault sign diagnosis system and a fault sign diagnosis method, which can reduce the collected measurement data, and can determine the component where the abnormality occurs and diagnose the fault sign of an object component composed of multiple components.

[0009] Means used to solve problems

[0010] As a first method for achieving the above-mentioned object, a fault sign diagnosis system is provided, which monitors the working state of a movable unit composed of multiple components and determines the fault signs of the components, wherein the fault sign diagnosis system comprises: an acoustic emission detection information acquisition unit, which acquires acoustic emission detection information, wherein the acoustic emission detection information indicates the detection status of the acoustic emission wave generated by the movable unit by the acoustic emission sensor; a vibration detection information acquisition unit, which acquires vibration detection information, wherein the vibration detection information indicates the detection status of the vibration generated in the component by the vibration sensor; and a fault sign recognition unit, which recognizes the fault sign of the component based on the acoustic emission detection information and the vibration detection information, after the movable unit starts to be used, the fault sign recognition unit performs a first monitoring process, and in the first monitoring process, the fault sign recognition unit performs a first monitoring process, wherein the first monitoring process is used. During the visual processing, an acoustic emission measurement process is repeatedly performed, and it is determined whether a first determination condition is met, that is, the number of times the acoustic emission wave is detected by the acoustic emission measurement process is greater than a predetermined number of determination times. The acoustic emission measurement process is a process in which the acoustic emission detection information is obtained by the acoustic emission detection information acquisition unit, and whether the acoustic emission wave is detected is identified based on the acoustic emission detection information. When the first determination condition is met, the fault sign identification unit ends the first monitoring process and performs a second monitoring process. In the second monitoring process, a vibration measurement process is repeatedly performed, and a fault sign of the component is identified based on the degree of increase in the vibration level of the component. The vibration measurement process is a process in which the vibration detection information is obtained by the vibration detection information acquisition unit, and the vibration level of the component is identified based on the vibration detection information.

[0011] In the above-mentioned fault sign diagnosis system, it can be configured as follows: the fault sign identification unit repeatedly executes the acoustic emission measurement process in the second monitoring process and determines whether a second determination condition is met, wherein the second determination condition is that the frequency of detecting the acoustic emission wave is greater than a predetermined determination frequency and the vibration level of the component identified by the vibration measurement process is greater than a predetermined determination level. When the second determination condition is met, the fault sign identification unit ends the second monitoring process and executes a third monitoring process. In the third monitoring process, the acoustic emission measurement process is not executed, and only the vibration measurement process is repeatedly executed. The fault sign of the component is identified based on the degree of increase in the vibration level of the component identified by the vibration measurement process.

[0012] The above-mentioned failure prediction system may be configured such that, in the first monitoring process, the failure prediction sign recognition unit executes the acoustic emission measurement process for a portion of a predetermined measurement period at each predetermined measurement period.

[0013] As a second method for achieving the above-mentioned purpose, a fault sign diagnosis method is provided, wherein the fault sign diagnosis method uses a computer to monitor the working status of a movable unit composed of multiple components and judge the fault signs of the components, wherein the fault sign diagnosis method includes: an acoustic emission detection information acquisition step of acquiring acoustic emission detection information, wherein the acoustic emission detection information indicates the detection status of the acoustic emission wave generated by the movable unit by the acoustic emission sensor; a vibration detection information acquisition step of acquiring vibration detection information, wherein the vibration detection information indicates the detection status of the vibration generated in the component by the vibration sensor; and a fault sign identification step of identifying the fault sign of the component based on the acoustic emission detection information and the vibration detection information, wherein the first monitoring step is performed after the movable unit starts to be used. In this first monitoring process, an acoustic emission measurement process is repeatedly executed, and it is determined whether a first determination condition is satisfied, namely, that the number of times the acoustic emission wave is detected by the acoustic emission measurement process is greater than or equal to a predetermined determination number. The acoustic emission measurement process is a process of obtaining the acoustic emission detection information through the acoustic emission detection information acquisition step and identifying whether the acoustic emission wave is detected based on the acoustic emission detection information. When the first determination condition is satisfied, the first monitoring process is terminated and a second monitoring process is executed. In this second monitoring process, a vibration measurement process is repeatedly executed, and a failure sign of the component is identified based on the degree of increase in the vibration level of the component. The vibration measurement process is a process of obtaining the vibration detection information through the vibration detection information acquisition step and identifying the vibration level of the component based on the vibration detection information.

[0014] Effects of the Invention

[0015] According to the above-described predicted-failure-evidence diagnosis system and predicted-failure-evidence diagnosis method, it is possible to reduce the amount of measurement data to be collected and to diagnose the predicted-failure-evidence of a target unit composed of a plurality of components by identifying a component in which an abnormality has occurred. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a diagram illustrating the structure of a failure prediction diagnosis system.

[0017] Figure 2 This diagram explains how to measure acoustic emission waves and vibrations in a power transmission unit.

[0018] Figure 3 This is a timing chart of the process of monitoring the operating status of the power transmission unit.

[0019] Figure 4 This is a first flowchart of the failure sign diagnosis process of the power transmission unit.

[0020] Figure 5This is a second flowchart of the failure sign diagnosis process of the power transmission unit.

[0021] Description of reference numerals:

[0022] 1... Fault sign diagnosis system, 10... Processor, 11... AE detection information acquisition unit, 12... Vibration detection information acquisition unit, 13... Fault sign identification unit, 20... Memory, 21... Program, 22... Component vibration / fault sign determination map, 30... Communication unit, 50... User terminal, 60... Service manager terminal, 100... Vehicle, 110... Vehicle control device, 160... Power transmission unit, 161... AE sensor, 162... Vibration sensor, 200... Communication network, 210... Vehicle manufacturer server, 211... Vehicle management DB (Data Base), 300... Automobile dealer, 310... Store management system, U... User, V... Service manager DETAILED DESCRIPTION

[0023] [1. Structure of the Fault Prediction Diagnosis System]

[0024] Reference Figure 1 、 Figure 2 The structure of the failure sign diagnosis system 1 of this embodiment will be described. The failure sign diagnosis system 1 monitors the operating state of the power transmission unit 160 of the vehicle 100 sold by the automobile dealer 300 and diagnoses the failure signs of the components constituting the power transmission unit 160.

[0025] Transactions include new vehicle sales, used vehicle sales, vehicle lease agreements, and the like. The power transmission unit 160 corresponds to the movable unit of the present disclosure. The fault prediction diagnostic system 1 is a computer system comprising a processor 10, a memory 20, a communication unit 30, and the like. The fault prediction diagnostic system 1 communicates via the communication unit 30 via a communication network 200 with a vehicle control device 110 mounted on the vehicle 100, a user terminal 50 used by a user U, a vehicle manufacturer server 210, and a store management system 310 of a car dealer 300.

[0026] like Figure 2As shown, the vehicle 100 has a motor 150 as a driving source; a power transmission unit 160 that transmits the driving force of the motor 150 to the wheels 151; and a vehicle control device 110 that controls the operation of the vehicle 100. In addition, the vehicle 100 has an acoustic emission sensor 161 and a plurality of vibration sensors 162. The acoustic emission sensor 161 detects acoustic emission waves generated when roughness, cracks, peeling, etc. occur in the power transmission unit 160, and the plurality of vibration sensors 162 detect vibrations generated in the components (bearings, gears, etc.) that constitute the power transmission unit 160 for each component. Figure 2 , three vibration sensors 162a, 162b, and 162c are exemplified as the vibration sensor 162.

[0027] Hereinafter, acoustic emission will also be referred to as AE (Acoustic Emission). Furthermore, vibration sensors 162a, 162b, and 162c will be collectively referred to as vibration sensors 162. Vibration sensors 162 detect vibrations in, for example, three axial directions (left-right, up-down, and front-back). AE sensors 161 and 162 are connected to vehicle control device 110, and their detection signals are input to vehicle control device 110.

[0028] The vehicle control device 110 includes a processor 111, a memory 112, a communication unit 114, and the like. The processor 111 reads and executes a program 113 for controlling the vehicle control device 110 stored in the memory 112, thereby controlling the operation of the vehicle 100. The vehicle control device 110 transmits AE detection information AEi indicating the detection status of AE waves by the AE sensor 161 and vibration detection information VBi indicating the detection status of component vibrations by the vibration sensor 162 to the early fault diagnosis system 1 via the communication unit 114.

[0029] Furthermore, the vehicle control device 110 transmits vehicle usage information Cui indicating the usage status of the vehicle 100 (such as travel distance, travel route, and driving operation status) to the vehicle manufacturer server 210. The store management system 310 and the service manager terminal 60 used by the service manager V of the automobile dealer 300 transmit maintenance information MTi indicating the details of maintenance performed on the vehicle 100 by the automobile dealer 300 to the vehicle manufacturer server 210.

[0030] The vehicle manufacturer server 210 receives the vehicle usage information CUi sent from the vehicle 100 and the maintenance information MTi sent from the shop management system 310, and records the vehicle usage information CUi and the maintenance information MTi in the vehicle management DB 211. Figure 1Although one vehicle 100 and one car dealer 300 are shown, in reality, the vehicle manufacturer server 210 communicates between multiple vehicles and the car dealer's shop management system, receives vehicle usage information CUi and maintenance information MTi for each of the multiple vehicles being managed, and records the information in the vehicle management DB 211.

[0031] The memory 20 of the predictive fault diagnosis system 1 stores a program 21 for controlling the predictive fault diagnosis system 1, as well as data for a component vibration / predictive fault sign determination chart 22. This chart is obtained by correlating the degree of increase in the vibration level of components constituting the power transmission unit 160 with the component's predicted fault sign level. This chart is created using previously measured correspondence data between the degree of increase in component vibration and the predicted fault sign level, computer simulation, and the like.

[0032] By reading and executing the program 21, the processor 10 functions as an AE detection information acquisition unit 11, a vibration detection information acquisition unit 12, and a predicted fault sign identification unit 13. The processing performed by the AE detection information acquisition unit 11 corresponds to the AE detection information acquisition step in the predicted fault sign diagnosis method disclosed herein. The processing performed by the vibration detection information acquisition unit 12 corresponds to the vibration detection information acquisition step in the predicted fault sign diagnosis method disclosed herein. The processing performed by the predicted fault sign identification unit 13 corresponds to the predicted fault sign identification step in the predicted fault sign diagnosis method disclosed herein.

[0033] The AE detection information acquisition unit 11 communicates with the vehicle 100 via the communication unit 30 to receive and acquire AE detection information AEi from the vehicle 100. The vibration detection information acquisition unit 12 communicates with the vehicle 100 via the communication unit 30 to receive and acquire vibration detection information VBi from the vehicle 100.

[0034] The fault sign identification unit 13 monitors the detection status of the AE wave generated from the power transmission unit 160 of the vehicle 100 and the vibration status of the components of the power transmission unit 160 based on the AE detection information AEi obtained by the AE detection information acquisition unit 11 and the vibration detection information VBi obtained by the vibration detection information acquisition unit 12, thereby identifying the fault signs of the components constituting the power transmission unit 160.

[0035] In addition, for the sake of convenience, Figure 1 , the figure shows a situation in which the failure sign diagnosis system 1 diagnoses the failure sign of the components constituting the power transmission unit 160 for one vehicle 100. However, in reality, the failure sign diagnosis system 1 communicates with a plurality of vehicles and diagnoses the failure of the components for each power transmission unit mounted on each vehicle.

[0036] In addition, Figure 1 In the embodiment, the predictive fault diagnosis system 1 receives the AE detection information AEi and the vibration detection information VBi through communication with the vehicle 100. However, the AE detection information AEi and the vibration detection information VBi may be sent from the vehicle 100 to the vehicle manufacturer server 210, and the AE detection information AEi and the vibration detection information VBi may be recorded in the vehicle management DB 211. In this case, the predictive fault diagnosis system 1 accesses the vehicle manufacturer server 210 to receive the AE detection information AEi and the vibration detection information VBi recorded in the vehicle management DB 211.

[0037] [2. Fault Predictive Diagnosis and Processing]

[0038] Reference Figure 3 As shown in the timing diagram, follow Figures 4 and 5 The flowchart shown explains the procedure of the predicted-failure-evidence diagnosis process of the components constituting the power transmission unit 160 of the vehicle 100 , which is executed by the predicted-failure-evidence diagnosis system 1 .

[0039] Figure 3 The time axis t is used to show the execution timing of the AE measurement processing and the vibration measurement processing. In the AE measurement processing, the presence or absence of the AE wave generated from the power transmission unit 160 of the vehicle 100 is measured based on the AE detection information AEi obtained by the AE detection information acquisition unit 11. In the vibration measurement processing, the vibration of the components constituting the power transmission unit 160 of the vehicle 100 is measured based on the vibration detection information VBi obtained by the vibration detection information acquisition unit 12.

[0040] exist Figure 4 In step S1, the predicted-failure-sign recognition unit 13 acquires AE detection information AEi from the vehicle 100 via the AE detection information acquisition unit 11 every minute (equivalent to the measurement cycle of the present disclosure) and performs AE measurement processing. In the following step S2, if the predicted-failure-sign recognition unit 13 detects an AE wave through the AE measurement processing, the processing proceeds to step S3; if no AE wave is detected through the AE measurement processing, the processing proceeds to step S1.

[0041] In step S3, the predicted fault sign recognition unit 13 increments the number of AE wave detections by 1 (+1). In the subsequent step S4, it is determined whether the number of AE wave detections is greater than the determination number. If the number of AE wave detections is greater than the determination number, the predicted fault sign recognition unit 13 proceeds to steps S5 and S20. If the number of AE wave detections is less than the determination number, the process proceeds to step S1.

[0042] like Figure 3As shown, through the processing of steps S1 to S4 (the first monitoring process), from t0, when monitoring of the power transmission unit 160 of the vehicle 100 begins, through t1, when the AE wave is first detected, to t2, when the number of AE wave detections exceeds the determination number, only the AE measurement process is executed, and the vibration measurement process is not performed. Thereafter, the AE measurement process is executed every minute. Since the AE measurement process takes only tens to hundreds of milliseconds (milliseconds), the amount of data collected, stored, and processed is small. Therefore, there is no need to prepare a large-scale data processing system capable of collecting, storing, and processing large amounts of data.

[0043] The failure sign recognition unit 13 performs the processing of steps S5 to S8 and the processing of steps S20 to S21 in parallel. The processing of steps S5 to S8 is performed for each component whose vibration is detected by the multiple vibration sensors 162 provided in the power transmission unit 160. In step S5, the failure sign recognition unit 13 obtains the vibration detection information VBi from the vehicle 100 through the vibration detection information acquisition unit 12 and performs vibration measurement processing. In the next step S6, the failure sign recognition unit 13 recognizes the time from the start of vibration measurement ( Figure 3 The degree of increase in the vibration level of the component starting from t2).

[0044] In the next step S7, the failure sign recognition unit 13 applies the degree of increase in the vibration level of the component to the component vibration / failure sign determination map 22 (see Figure 1 ) to identify the fault sign level of the component. In the next step S8, the fault sign identification unit 13 determines whether the component needs maintenance based on the fault sign level of the component. Then, the fault sign identification unit 13 enters the processing when the component needs maintenance. Figure 5 In step S14 , the maintenance recommendation information MRi for recommending maintenance is sent to the user terminal 50 , thereby prompting the user U to accept the maintenance of the power transmission unit 160 .

[0045] Alternatively, the maintenance recommendation information MRi may be sent to the vehicle control device 110 to display an image of recommended maintenance on a display device of the vehicle 100. Alternatively, the maintenance recommendation information MRi may be sent to the store management system 310 to have the service manager V notify the user U of the recommended maintenance.

[0046] On the other hand, if it is determined that component maintenance is not yet necessary, the predicted-failure-sign recognition unit 13 advances the process to step S9. Furthermore, in step S20, the predicted-failure-sign recognition unit 13 acquires AE detection information AEi from the vehicle 100 every minute via the AE detection information acquisition unit 11, thereby performing AE measurement. In the following step S21, the predicted-failure-sign recognition unit 13 identifies the AE wave detection frequency based on the AE measurement (the proportion of the number of AE measurements in which the AE wave was detected, out of a predetermined number of AE measurements), and then advances the process to step S9.

[0047] In step S9, the fault sign recognition unit 13 determines whether the second judgment condition is satisfied, that is, the vibration level of the measured component is above the judgment level and the detection frequency of the AE wave is above the judgment frequency. Then, the fault sign recognition unit 13 enters the process when the second judgment condition is satisfied. Figure 5 In step S10, when the second determination condition is not satisfied, the process proceeds to step S5.

[0048] like Figure 3 As shown, through the processing of steps S5-S9 and steps S20-S21 (second monitoring process), the vibration measurement process is initiated at t2, when the number of AE wave detections exceeds the determination number, and it is estimated that the deterioration of power transmission unit 160 has progressed. Subsequently, between t2 and t3, the AE measurement process and the vibration measurement process are executed, and the AE wave detection frequency obtained by the AE measurement process and the vibration levels of the components of power transmission unit 160 obtained by the vibration measurement process are monitored.

[0049] In the second monitoring process, the vibration measurement process can identify and recognize failure signs of components constituting the power transmission unit 160. In addition, the increased possibility of failure of the power transmission unit 160 can be recognized based on the detection frequency of the AE wave obtained by the AE measurement process.

[0050] exist Figure 5 In step S10, the failure sign recognition unit 13 obtains the vibration detection information VBi from the vehicle 100 through the vibration detection information acquisition unit 12 and performs vibration measurement processing. In the next step S11, the failure sign recognition unit 13 recognizes the time from the start of the vibration measurement processing ( Figure 3 The degree of increase in the vibration level of the component starting from t2).

[0051] In the next step S12, the failure sign recognition unit 13 applies the degree of increase in the vibration level of the component to the component vibration / failure sign determination map 22 (see Figure 1 ) to identify the predicted failure sign level of the component. In the next step S13, the predicted failure sign identification unit 13 determines whether the component needs maintenance based on the predicted failure sign level of the component.

[0052] Then, if component maintenance is required, the failure sign recognition unit 13 advances the process to step S14 and transmits maintenance recommendation information MRi recommending maintenance to the user terminal 50, thereby prompting the user U to perform maintenance on the power transmission unit 160. On the other hand, if it is determined that component maintenance is not required, the failure sign recognition unit 13 advances to step S10 and continues to monitor the vibration levels of the components constituting the power transmission unit 160.

[0053] like Figure 3 As shown, through the processing of steps S10 to S13 (the third monitoring processing), the detection frequency of the AE wave is increased due to the establishment of the second judgment condition, so that the state in which the possibility of failure of the power transmission unit 160 is high continues. In addition, when it can be estimated that the possibility of component failure increases due to the increase in vibration level, the AE measurement processing is terminated and monitoring is continued only through the vibration measurement processing.

[0054] [3. Other Implementation Methods]

[0055] In the above embodiment, the power transmission unit 160 of the vehicle 100 is used as an example of the movable unit of this embodiment. However, the movable unit of this embodiment can be any movable unit that can measure AE waves and vibrations. For example, it can be a mobile object other than a vehicle (such as an aircraft or a ship).

[0056] In the above embodiment, if Figure 3 As shown, the operating status of the power transmission unit 160 is monitored as follows: starting at t0 when the power transmission unit 160 begins to be used, a first monitoring process is initiated, in which only AE measurements are performed without vibration measurement. At t2, when the first determination condition is satisfied, the process switches to a second monitoring process in which both vibration and AE measurements are performed. Furthermore, at t3, when the second determination condition is satisfied, the process switches to a third monitoring process in which only vibration measurements are performed without AE measurements. In another embodiment, after switching from the first monitoring process to the second monitoring process, the second determination condition may not be determined, but the second monitoring process may continue to monitor the operating status of the power transmission unit 160.

[0057] In the above embodiment, the disclosed predictive fault diagnosis system is illustrated as comprising the predictive fault diagnosis system 1 communicating with the vehicle 100. Alternatively, the vehicle 100 may include the predictive fault diagnosis system. Furthermore, the disclosed predictive fault diagnosis system may be incorporated into the vehicle manufacturer's server 210 or the store management system 310.

[0058] in addition, Figure 1In order to facilitate understanding of the present invention, the schematic diagram of the structure of the fault sign diagnosis system 1 is distinguished and shown by the main processing content. The fault sign diagnosis system 1 can also be constructed according to other distinction methods. In addition, the processing of each component can be executed by one hardware unit or by multiple hardware units. In addition, Figure 4 、 Figure 5 The processing performed by each of the components shown may be executed by one program or by a plurality of programs.

[0059] [4. Structures Supported by the Above-mentioned Embodiments]

[0060] The above-described embodiment is a specific example of the following structure.

[0061] (Structure 1) A fault sign diagnosis system that monitors the working state of a movable unit composed of multiple components and determines the fault signs of the components, wherein the fault sign diagnosis system comprises: an acoustic emission detection information acquisition unit that acquires acoustic emission detection information, the acoustic emission detection information indicating the detection status of the acoustic emission wave generated by the movable unit by the acoustic emission sensor; a vibration detection information acquisition unit that acquires vibration detection information, the vibration detection information indicating the detection status of the vibration generated in the component by the vibration sensor; and a fault sign identification unit that identifies the fault sign of the component based on the acoustic emission detection information and the vibration detection information, wherein after the movable unit starts to be used, the fault sign identification unit performs a first monitoring process, in which the first monitoring process is repeatedly performed. An acoustic emission measurement process is performed, and it is determined whether a first determination condition is met, that is, the number of times the acoustic emission wave is detected by the acoustic emission measurement process is greater than a predetermined determination number. The acoustic emission measurement process is a process in which the acoustic emission detection information is acquired by the acoustic emission detection information acquisition unit and whether the acoustic emission wave is detected is identified based on the acoustic emission detection information. When the first determination condition is met, the fault sign identification unit ends the first monitoring process and performs a second monitoring process. In the second monitoring process, a vibration measurement process is repeatedly performed, and a fault sign of the component is identified based on the degree of increase in the vibration level of the component. The vibration measurement process is a process in which the vibration detection information is acquired by the vibration detection information acquisition unit and the vibration level of the component is identified based on the vibration detection information.

[0062] According to the failure prediction diagnosis system of configuration 1, after the start of use of the movable unit, until the first determination condition is satisfied and the probability of failure of the movable unit is estimated to be high enough, only acoustic emission measurement processing is performed through the first monitoring process. This reduces the load of collecting and processing measurement data compared to the case where vibration measurement processing is performed from the start of use of the movable unit. Subsequently, after the first determination condition is satisfied, vibration measurement processing is performed to identify the component and perform failure prediction diagnosis.

[0063] (Structure 2) According to the fault sign diagnosis system of Structure 1, the fault sign identification unit repeatedly executes the acoustic emission measurement process in the second monitoring process and determines whether the second judgment condition is met, and the second judgment condition is: the frequency of detecting the acoustic emission wave is greater than or equal to a predetermined judgment frequency, and the vibration level of the component identified by the vibration measurement process is greater than or equal to a predetermined judgment level. When the second judgment condition is met, the fault sign identification unit ends the second monitoring process and executes a third monitoring process. In the third monitoring process, the acoustic emission measurement process is not executed, and only the vibration measurement process is repeatedly executed. The fault sign of the component is identified based on the degree of increase in the vibration level of the component identified by the vibration measurement process.

[0064] According to the fault prediction diagnosis system of structure 2, when it is estimated that the possibility of further deterioration of the movable unit is further increased due to the establishment of the second judgment condition, the acoustic emission measurement processing is terminated and switched to the third monitoring processing of only performing the vibration measurement processing, thereby reducing the load of collecting and processing the measurement data.

[0065] (Configuration 3) According to the predicted failure sign diagnosis system of Configuration 1 or Configuration 2, the predicted failure sign identification unit executes the acoustic emission measurement process for a portion of the measurement period at each predetermined measurement period in the first monitoring process.

[0066] According to the fault indication diagnosis system of structure 3, the interval for executing the acoustic emission measurement process can be set to be longer than the time required for the acoustic emission measurement process, thereby enabling the acoustic emission measurement process to be performed intermittently, reducing the load of data collection and data processing based on the acoustic emission measurement process.

[0067] (Structure 4) A fault sign diagnosis method, which uses a computer to monitor the working status of a movable unit composed of multiple components and judge the fault signs of the components, wherein the fault sign diagnosis method includes: an acoustic emission detection information acquisition step, which acquires acoustic emission detection information, wherein the acoustic emission detection information indicates the detection status of the acoustic emission wave generated by the movable unit by the acoustic emission sensor; a vibration detection information acquisition step, which acquires vibration detection information, wherein the vibration detection information indicates the detection status of the vibration generated in the component by the vibration sensor; and a fault sign identification step, which identifies the fault sign of the component based on the acoustic emission detection information and the vibration detection information, wherein in the fault sign identification step, after the movable unit starts to be used, a first monitoring process is performed, and in the first monitoring process, the first monitoring process is performed. In the first monitoring process, an acoustic emission measurement process is repeatedly performed, and it is determined whether a first determination condition is met, that is, the number of times the acoustic emission wave is detected by the acoustic emission measurement process is greater than or equal to a predetermined determination number. The acoustic emission measurement process is a process of obtaining the acoustic emission detection information through the acoustic emission detection information acquisition step and identifying whether the acoustic emission wave is detected based on the acoustic emission detection information. When the first determination condition is met, the first monitoring process is terminated and a second monitoring process is performed. In the second monitoring process, a vibration measurement process is repeatedly performed, and a failure sign of the component is identified based on the degree of increase in the vibration level of the component. The vibration measurement process is a process of obtaining the vibration detection information through the vibration detection information acquisition step and identifying the vibration level of the component based on the vibration detection information.

[0068] By executing the predicted-failure-evidence diagnosis method of the fourth configuration using a computer, the same operational effects as those of the predicted-failure-evidence diagnosis system of the first configuration can be obtained.

Claims

1. A fault sign diagnosis system, wherein the fault sign diagnosis system monitors the working state of a movable unit composed of multiple components and determines the fault signs of the components, wherein: The fault prediction diagnosis system comprises: an acoustic emission detection information acquisition unit that acquires acoustic emission detection information indicating a detection status of an acoustic emission wave generated from the movable unit by an acoustic emission sensor; a vibration detection information acquisition unit configured to acquire vibration detection information indicating a detection status of vibration occurring in the component by the vibration sensor; as well as a failure sign recognition unit that recognizes a failure sign of the component based on the acoustic emission detection information and the vibration detection information, After the movable unit starts to be used, the failure sign recognition unit performs a first monitoring process, in which an acoustic emission measurement process is repeatedly performed to determine whether a first determination condition is satisfied, that is, the number of times the acoustic emission wave is detected by the acoustic emission measurement process is greater than or equal to a predetermined determination number. The acoustic emission measurement process is a process in which the acoustic emission detection information acquisition unit acquires the acoustic emission detection information and determines whether the acoustic emission wave is detected based on the acoustic emission detection information. When the first judgment condition is met, the fault sign identification unit ends the first monitoring process and executes the second monitoring process. In the second monitoring process, the vibration measurement process is repeatedly executed, and the fault sign of the component is identified according to the increase in the vibration level of the component. The vibration measurement process is a process of obtaining the vibration detection information through the vibration detection information acquisition unit and identifying the vibration level of the component according to the vibration detection information.

2. The fault prediction diagnosis system according to claim 1, wherein: The failure sign identification unit repeatedly executes the acoustic emission measurement process in the second monitoring process and determines whether a second determination condition is satisfied, wherein the second determination condition is that the frequency of detecting the acoustic emission wave is equal to or higher than a predetermined determination frequency and the vibration level of the component identified by the vibration measurement process is equal to or higher than a predetermined determination level. When the second judgment condition is met, the fault sign identification unit ends the second monitoring process and executes the third monitoring process. In the third monitoring process, the acoustic emission measurement process is not executed, and only the vibration measurement process is repeatedly executed. The fault sign of the component is identified based on the degree of increase in the vibration level of the component identified by the vibration measurement process.

3. The fault prediction diagnosis system according to claim 1 or 2, wherein: The predicted-failure-sign identifying unit executes the acoustic emission measurement process during a portion of the predetermined measurement cycle in the first monitoring process at each predetermined measurement cycle.

4. A method for diagnosing a fault sign, wherein the method uses a computer to monitor the working state of a movable unit composed of multiple components and judge the fault signs of the components, wherein: The fault premonition diagnosis method comprises: an acoustic emission detection information obtaining step of obtaining acoustic emission detection information, wherein the acoustic emission detection information indicates a detection status of an acoustic emission wave generated from the movable unit by an acoustic emission sensor; a vibration detection information acquisition step of acquiring vibration detection information indicating a detection condition of vibration occurring in the component by a vibration sensor; and a fault sign identification step of identifying the fault sign of the component based on the acoustic emission detection information and the vibration detection information, In the fault sign identification step, After the movable unit starts to be used, a first monitoring process is executed. In the first monitoring process, an acoustic emission measurement process is repeatedly executed, and it is determined whether a first determination condition is satisfied, that is, the number of times the acoustic emission wave is detected by the acoustic emission measurement process is greater than or equal to a predetermined determination number. The acoustic emission measurement process is a process of obtaining the acoustic emission detection information by the acoustic emission detection information acquisition step and identifying whether the acoustic emission wave is detected based on the acoustic emission detection information. When the first judgment condition is met, the first monitoring process is terminated and the second monitoring process is executed. In the second monitoring process, the vibration measurement process is repeatedly executed, and the failure sign of the component is identified based on the increase in the vibration level of the component. The vibration measurement process is a process of obtaining the vibration detection information through the vibration detection information acquisition step and identifying the vibration level of the component based on the vibration detection information.

Images