Equipment maintenance monitoring method and system

Abstract

The invention provides an equipment maintenance monitoring method and system, which are characterized in that proximity switches are arranged at key parts needing regular maintenance, state signals of the proximity switches are sent to a PLC (Programmable Logic Controller), the PLC acquires the state signals of the proximity switches in real time, and according to a preset standard maintenance period of each key part, the maintenance time of each key part is shortened; judging whether the state signal of the proximity switch at each key component changes in the corresponding preset standard maintenance period, and if not, judging that the corresponding key component in the preset standard maintenance period is not maintained; the position information of the key component is automatically detected through the state change of the proximity switch, a state signal of the proximity switch is sent to the PLC to judge whether the state signal changes in a preset marked maintenance period or not, if the state signal changes, it is judged that the key component is maintained, and if the state signal does not change, it is judged that the key component is not maintained; maintenance conditions of key components are automatically detected and judged, and tracking recording and unified management are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment maintenance, and in particular to a monitoring method and system for equipment maintenance. Background Art

[0002] In modern manufacturing, the operational stability and production efficiency of automated equipment are highly dependent on regular maintenance and upkeep. Traditional equipment maintenance relies heavily on manual record-keeping and inspection systems, which can be plagued by issues such as inadequate execution, inaccurate records, and lagging oversight. Especially in continuously operating production lines, failure to maintain key components regularly can lead to increased equipment wear, increased failure rates, and even serious downtime.

[0003] Currently, some companies use electronic work orders or QR code sign-in methods to digitally record maintenance activities, but these methods still rely on active human operation and cannot truly achieve process control and closed-loop management. Summary of the Invention

[0004] The present invention provides a monitoring method and system for equipment maintenance, which automatically detects the maintenance status of key components of equipment and realizes tracking, recording and unified management.

[0005] In a first aspect, the present invention provides a method for monitoring equipment maintenance, comprising:

[0006] Proximity switches are installed at key components that require regular maintenance, and status signals of the proximity switches are sent to the PLC controller;

[0007] The PLC controller collects the status signal of the proximity switch in real time, and determines whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle according to the preset standard maintenance cycle of each key component;

[0008] If no change occurs, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle.

[0009] In one embodiment, if no change occurs and it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle, the method further includes:

[0010] The host computer reads the maintenance status information of each key component in the PLC controller;

[0011] Based on the maintenance status information, a reminder notification is automatically sent to relevant personnel of the key components that have not been maintained.

[0012] In one embodiment, when the device is a motherboard production device, after automatically sending a reminder notification to relevant personnel of unmaintained key components based on the maintenance status information, the method further includes:

[0013] The host computer automatically sends instructions to the PLC controller to control the board placement device to stop the board placement action;

[0014] When receiving the status information that the maintenance of the unmaintained key component has been completed, the host computer automatically sends an instruction to the PLC controller to resume the board placement action of the board placement device.

[0015] In one embodiment, the host computer includes a human-computer interaction interface. After the host computer reads the maintenance status information of each key component in the PLC controller, the host computer further includes:

[0016] Stores the maintenance status information of each key component and displays the current maintenance status and remaining maintenance time of each key component.

[0017] In one embodiment, the host computer supports historical query and report generation functions for maintenance status information of each key component.

[0018] In one embodiment, the human-computer interaction interface of the host computer also provides manual reset, alarm confirmation and parameter setting functions.

[0019] In one embodiment, the PLC controller includes a human-machine interface, through which the preset standard maintenance cycle of each key component can be set and modified.

[0020] On the other hand, the present invention also provides a monitoring system for equipment maintenance, comprising:

[0021] A proximity switch detection module is provided at each key component requiring regular maintenance, and is used to generate a status signal based on the position information of each key component and send the status signal to the PLC control module;

[0022] The PLC control module is arranged in the PLC controller and is used to collect the status signal of the proximity switch detection module in real time, and judge whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle according to the preset standard maintenance cycle of each key component. If no change occurs, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle.

[0023] In one embodiment, a host management module is further included, which is set in the host computer and is used to read the maintenance status information of each key component in the PLC control module, and automatically send reminder notifications to relevant personnel of the unmaintained key components based on the maintenance status information.

[0024] In one embodiment, it also includes an equipment linkage control module, which is arranged in the upper computer and connected to the upper management module. When the equipment is a motherboard production equipment, it is used to automatically send instructions to the PLC control module of the PLC controller to control the board placement equipment to stop the board placement action. When receiving the status information that the maintenance of the unmaintained key component is completed, the upper computer automatically sends instructions to the PLC control module to resume the board placement action of the board placement equipment.

[0025] The present invention provides a monitoring method and system for equipment maintenance. A proximity switch is provided at each key component that requires regular maintenance, and a status signal of the proximity switch is sent to a PLC controller. The PLC controller collects the status signal of the proximity switch in real time, and determines whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle based on the preset standard maintenance cycle of each key component. If not, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle; the position information of the key component is automatically detected by the status change of the proximity switch, and the status signal of the proximity switch is sent to the PLC controller to determine whether the status signal changes within the preset marked maintenance cycle. If it changes, it is determined that maintenance has been performed; if not, it is determined that maintenance has not been performed; the maintenance status of the key components is automatically detected and determined to achieve tracking, recording and unified management. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. The drawings described below are only drawings corresponding to some embodiments of the present invention. For ordinary technicians in this field, without paying any creative work, they can also obtain drawings of other embodiments based on these drawings.

[0027] Figure 1 A flowchart of a method for monitoring equipment maintenance in one embodiment of the present invention;

[0028] Figure 2 A flowchart of a method for monitoring equipment maintenance in another embodiment of the present invention;

[0029] Figure 3 This is a system block diagram of a monitoring system for equipment maintenance in one embodiment of the present invention. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of the present invention.

[0031] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0032] See also Figure 1 The present invention provides a method for monitoring equipment maintenance, in one embodiment of which the method comprises:

[0033] S101, a proximity switch is installed at each key component that requires regular maintenance, and a status signal of the proximity switch is sent to a PLC controller.

[0034] Specifically, the equipment can be PCB mainboard production equipment, whose key components, such as lubrication points, filter replacement points, and transmission mechanisms, require regular maintenance to ensure the production quality of the PCB mainboards. The equipment used in the method of this embodiment is not limited to PCB mainboard production equipment, but can also be any other production equipment that requires regular equipment maintenance.

[0035] The proximity switch is set at the location of each key component that requires regular maintenance. When the key component is removed, the status signal of the proximity switch will change.

[0036] S102, the PLC controller collects the status signal of the proximity switch in real time, and determines whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle according to the preset standard maintenance cycle of each key component.

[0037] S103: If there is no change, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle.

[0038] The PLC controller is connected to the proximity switch and collects its status signals in real time. The PLC controller pre-sets and stores standard maintenance cycles for key components. For example, the standard maintenance cycle for lubrication points is every 8 hours. The PLC controller determines whether the status signal of the proximity switch at the lubrication point changes during this maintenance cycle. If no change occurs, the lubrication point is determined not to have been maintained during this maintenance cycle. If a change occurs, it is determined that the lubrication point has been maintained.

[0039] The judgment logic of other key components is consistent, but due to their different standard maintenance cycles, the judgment time points are different. The PLC controller monitors the maintenance status of different key components at the same time to achieve multi-threaded parallel management.

[0040] In one embodiment, the PLC controller includes a human-machine interface, through which the preset standard maintenance cycle of each key component can be set and modified.

[0041] The equipment maintenance monitoring method of this embodiment provides a proximity switch at a key component. When a key component is removed for maintenance, the status signal of the proximity switch changes. If the key component is not removed, the status signal of the proximity switch does not change. Therefore, the status change of the proximity switch can be used as a basis for determining whether the key component has been maintained. The PLC controller collects the status signal of the proximity switch in real time and determines whether the status signal of the proximity switch changes within the preset standard maintenance cycle corresponding to each key component. If the status signal changes, it indicates that the key component has been maintained within the preset standard maintenance cycle. If the status signal does not change, it is determined that the key component has not been maintained. This method can realize real-time detection and judgment of the maintenance status of each key component, achieving unified monitoring and management.

[0042] See also Figure 2 In one embodiment, the method for monitoring equipment maintenance includes:

[0043] S201, installing a proximity switch at each key component requiring regular maintenance, and sending a status signal of the proximity switch to a PLC controller.

[0044] Furthermore, the proximity switch is a proximity switch detection module and is connected to a PLC controller. The proximity switch detection module is independently set and is easy to integrate into an existing production line. Different models can be used according to the type of key components to better detect position changes of key components and thereby realize maintenance detection.

[0045] S202, the PLC controller collects the status signal of the proximity switch in real time, and determines whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle according to the preset standard maintenance cycle of each key component.

[0046] S203: If there is no change, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle.

[0047] Furthermore, the PLC controller can also record the maintenance time of key components based on the duration of the proximity switch status signal change, which serves as a detection indicator for whether the maintenance complies with the regulations, thereby improving the monitoring of maintenance and ensuring better maintenance of the equipment.

[0048] S204: The host computer reads the maintenance status information of each key component in the PLC controller.

[0049] S205: Automatically send reminder notifications to relevant personnel of the unmaintained key components based on the maintenance status information.

[0050] The host computer reads the maintenance status information in the PLC controller through protocols such as OPC UA or Modbus TCP, and sets maintenance reminder rules in advance. When it is found that the equipment or a key component has not been maintained, it automatically sends an email or SMS notification to the relevant personnel.

[0051] S205, the host computer automatically sends an instruction to the PLC controller to control the board placement device to stop the board placement action.

[0052] S205, upon receiving the status information that the maintenance of the unmaintained key component has been completed, the host computer automatically sends an instruction to the PLC controller to resume the board placement action of the board placement device.

[0053] If maintenance on a critical component is not completed within the specified timeframe, the host computer enters forced control mode. For example, in PCB production equipment, the host computer automatically sends a command to the PLC controller to stop the board placement mechanism, halting production on the PCB production line and preventing product quality issues. Upon detecting that maintenance has been completed on an unmaintained critical component, the host computer automatically sends a command to the PLC controller to resume the board placement mechanism, returning the production line to normal operation and ensuring product quality.

[0054] In one embodiment, the host computer supports historical query and report generation functions for maintenance status information of each key component, facilitating historical tracing and information review.

[0055] In one embodiment, the human-computer interaction interface of the host computer also provides manual reset, alarm confirmation and parameter setting functions.

[0056] Specifically, if staff discover that a critical component has exceeded maintenance requirements, they can use the manual reset menu to force the equipment to stop, ensuring production quality. The human-machine interface also provides an alarm function; clicking the alarm confirmation menu automatically triggers an alarm. The parameter setting function allows you to set standard maintenance cycles for each key component and send these to the PLC controller, changing the preset standard maintenance cycles or other control parameters. These functions facilitate comprehensive monitoring of the maintenance process and production line control via the host computer, creating a closed-loop control system between maintenance inspections and production equipment.

[0057] The equipment maintenance monitoring method of this embodiment uses proximity switches to detect the maintenance status of key components. A PLC controller performs maintenance logic judgment and equipment start-stop control. A host computer reads the maintenance status information of the equipment and key components from the PLC controller, automatically notifying relevant personnel and issuing alarms, as well as commands to the PLC controller to force unmaintained equipment to stop operating, ensuring product quality. This complete closed-loop control between maintenance monitoring and production equipment is achieved. The host computer's human-machine interface also supports display functions such as information display, historical query, and report generation, as well as operational functions such as parameter setting, alarm confirmation, and manual reset, making the equipment maintenance monitoring process more comprehensive, intelligent, and efficient.

[0058] See also Figure 3 , the embodiment of the present application further proposes a monitoring system for equipment maintenance, comprising:

[0059] The proximity switch detection module 10 is provided at each key component that requires regular maintenance, and is used to generate a status signal according to the position information of each key component, and send the status signal to the PLC control module 201 .

[0060] The PLC control module 201 is provided in the PLC controller 20 and is used to collect the status signal of the proximity switch detection module 10 in real time, and determine whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle according to the preset standard maintenance cycle of each key component. If no change occurs, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle.

[0061] In one embodiment, the system further includes a host management module 301, which is provided in the host computer 30 and is used to read the maintenance status information of each key component in the PLC control module 201, and automatically send reminder notifications to relevant personnel of the unmaintained key components based on the maintenance status information.

[0062] In one embodiment, the system also includes an equipment linkage control module 302, which is arranged in the host computer 30 and connected to the host management module 301. When the equipment is a motherboard production equipment, it is used to automatically send instructions to the PLC control module 201 of the PLC controller to control the board placement equipment 40 to stop the board placement action. When receiving the status information that the maintenance of the unmaintained key components is completed, the host computer automatically sends instructions to the PLC control module 201 to resume the board placement action of the board placement equipment 40.

[0063] Among them, the PLC control module 201, the upper management module 301 and the device linkage control module 302 are all independent software program modules, which can reduce the coupling relationship with other programs in the device and facilitate subsequent upgrades and maintenance.

[0064] In one embodiment, the host computer 30 includes a human-computer interaction interface, and the host management module 301 is further used to store maintenance status information of each key component. The human-computer interaction interface is used to display the current maintenance status and remaining maintenance time of each key component.

[0065] In one embodiment, the upper management module 301 also supports historical query and report generation functions for maintenance status information of each key component.

[0066] In one embodiment, the human-computer interaction interface of the host computer 30 also provides manual reset, alarm confirmation and parameter setting functions.

[0067] In one embodiment, the PLC controller includes a human-machine interface, through which the preset standard maintenance cycle of each key component can be set and modified.

[0068] The equipment maintenance monitoring system of the embodiment of the present application combines the proximity switch detection module, PLC controller, host computer and communication network to build a complete intelligent maintenance monitoring system, which not only provides early warning prompts, but also can force the equipment to stop operating according to the strategy, effectively preventing equipment damage and product quality problems caused by lack of maintenance. The entire maintenance life cycle of the equipment can be recorded and queried, making management more standardized and efficient, reducing manual management costs and the risk of misjudgment. The modular design of each function is easy to integrate into existing equipment, reducing coupling with other functions in the equipment, and facilitating subsequent upgrades and maintenance. The system has positive significance for the timely maintenance of production line equipment and product quality assurance.

[0069] In the above embodiments provided by the present invention, it should be understood that the disclosed systems, devices and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of the units is merely a logical function division. In actual implementation, there may be other division methods, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interface, device or unit, which can be electrical, mechanical or other forms.

[0070] The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of these units may be selected to achieve the purpose of this embodiment according to actual needs.

[0071] In addition, the functional units in the various embodiments of the present application may be integrated into a processing unit, or each unit may exist physically separately, or two or more units may be integrated into a single unit. The aforementioned integrated units may be implemented in the form of hardware or in the form of software functional units. If the integrated units are implemented in the form of software functional units and sold or used as independent products, they may be stored in a computer-readable storage medium.

[0072] Based on this understanding, the technical solution of this application, or the contributing part, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes a number of instructions for causing a computer device (which can be a mobile terminal, personal computer, server, or network device, etc.) to execute all or part of the steps of the method described in each embodiment of this application. The aforementioned storage medium includes: a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk, etc., various media that can store program code.

[0073] In summary, although the present invention has been disclosed as above in terms of preferred embodiments, the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the concept of the technical solution of the present invention, should be covered by the scope of protection of the present invention.

[0074] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned 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 method for monitoring equipment maintenance, characterized in that: include: Proximity switches are installed at key components that require regular maintenance, and status signals of the proximity switches are sent to the PLC controller; The PLC controller collects the status signal of the proximity switch in real time, and determines whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle according to the preset standard maintenance cycle of each key component; If no change occurs, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle.

2. The method according to claim 1, characterized in that If no change occurs, after determining that the corresponding key component has not been maintained within the preset standard maintenance cycle, the method further includes: The host computer reads the maintenance status information of each key component in the PLC controller; Based on the maintenance status information, a reminder notification is automatically sent to relevant personnel of the key components that have not been maintained.

3. The method according to claim 2, characterized in that When the equipment is a motherboard production equipment, after automatically sending a reminder notification to relevant personnel of the key components that have not been maintained based on the maintenance status information, the following further includes: The host computer automatically sends instructions to the PLC controller to control the board placement device to stop the board placement action; When receiving the status information that the maintenance of the unmaintained key component has been completed, the host computer automatically sends an instruction to the PLC controller to resume the board placement action of the board placement device.

4. The method according to claim 2, characterized in that The host computer includes a human-computer interaction interface. After the host computer reads the maintenance status information of each key component in the PLC controller, it also includes: Stores the maintenance status information of each key component and displays the current maintenance status and remaining maintenance time of each key component.

5. The method according to claim 4, characterized in that The host computer supports historical query and report generation functions of maintenance status information of each key component.

6. The method according to claim 4, characterized in that The human-machine interaction interface of the host computer also provides manual reset, alarm confirmation and parameter setting functions.

7. The method according to claim 1, characterized in that The PLC controller includes a human-machine interaction interface, through which the preset standard maintenance cycle of each key component can be set and modified.

8. A monitoring system for equipment maintenance, characterized in that: include: A proximity switch detection module is provided at each key component requiring regular maintenance, and is used to generate a status signal based on the position information of each key component and send the status signal to the PLC control module; The PLC control module is arranged in the PLC controller and is used to collect the status signal of the proximity switch detection module in real time, and judge whether the status signal of the proximity switch at each key component changes within the corresponding preset standard maintenance cycle according to the preset standard maintenance cycle of each key component. If no change occurs, it is determined that the corresponding key component has not been maintained within the preset standard maintenance cycle.

9. The system according to claim 8, characterized in that It also includes an upper management module, which is set in the upper computer and is used to read the maintenance status information of each key component in the PLC control module, and automatically send reminder notifications to relevant personnel of the key components that have not been maintained based on the maintenance status information.

10. The system according to claim 9, characterized in that It also includes an equipment linkage control module, which is arranged in the upper computer and connected to the upper management module. When the equipment is a motherboard production equipment, it is used to automatically send instructions to the PLC control module of the PLC controller to control the board placement equipment to stop the board placement action. When the status information of the maintenance of the unmaintained key components is received, the upper computer automatically sends instructions to the PLC control module to resume the board placement action of the board placement equipment.

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