Fault early warning method and system for advertisement printing equipment

Abstract

The invention discloses a fault early warning method and system for advertisement printing equipment, and relates to the technical field of automation control, and the method comprises the steps: obtaining a control instruction variable quantity and a feedback deviation variable quantity of the advertisement printing equipment, and calculating an available control margin reference; using the control instruction variation and the feedback deviation variation to calculate the current control output regulation quantity as the instantaneous control margin consumption; selectively accumulating the instantaneous control margin consumption by using a gating health memory mechanism to obtain a health index; calculating the evolution rate of the health state of the equipment by using the health index, and calculating an available health time window of the advertisement printing equipment; according to the method, the available control margin reference is constructed through the control instruction variable quantity and the feedback deviation variable quantity, so that the attenuation of the control capability is converted into a continuously traceable margin consumption process from a deviation phenomenon, the interpretability and comparability of early degradation identification are improved, and the quantization of control margin degradation is realized.

Description

Technical Field

[0001] This invention relates to the field of automation control technology, and in particular to a fault early warning method and system for advertising printing equipment. Background Technology

[0002] Driven by roll-to-roll continuous production, tension closed-loop control, and high-speed synchronous drive technologies, advertising printing equipment has gradually formed a control system with motion controllers at its core and tension sensors and actuators working in tandem. Currently, engineering applications often employ discrete control laws such as incremental PID controllers to adjust for changes in control commands and feedback deviations. These are combined with process parameters such as limit adjustment margins, alarm thresholds, operating speed, and tension settings to achieve online monitoring and protection of tension stability and printing quality.

[0003] There are still areas for improvement in the existing technology. First, the existing fault warning system is unable to characterize the continuous consumption of "control margin" during the degradation process, making it difficult to quantify the degradation of control margin. Second, the existing methods lack an interpretable calculation mechanism for the degradation evolution rate and available operating time, making it difficult to predict the available health time window. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, the present invention provides a fault early warning method for advertising printing equipment to solve the problems of difficulty in quantifying control margin degradation and difficulty in predicting available health time windows.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0007] In a first aspect, the present invention provides a fault early warning method for advertising printing equipment, comprising,

[0008] Obtain the change in control command and the change in feedback deviation of the advertising printing equipment, calculate the available control margin reference, and use the change in control command and the change in feedback deviation to calculate the current control output adjustment as the instantaneous control margin consumption.

[0009] A health index is obtained by selectively accumulating the instantaneous control margin consumption using a gated health memory mechanism.

[0010] The health index is used to calculate the rate of change in the health status of the equipment and to estimate the available health time window for the advertising printing equipment.

[0011] Based on the available health time window, the advertising printing equipment is divided into any of the following health levels: normal, attention, warning, and critical. Corresponding fault warning information and corresponding operation management measures are generated according to the health level.

[0012] As a preferred embodiment of the fault early warning method for the advertising printing equipment described in this invention, the control command change and the feedback deviation change are superimposed according to the discrete incremental control law to obtain the control output adjustment amount.

[0013] The limit adjustment margin is set based on the historical control output adjustment, and the available control margin benchmark is calculated using the control output adjustment and the limit adjustment margin.

[0014] In a preferred embodiment of the fault early warning method for the advertising printing equipment described in this invention, the specific steps for superimposing the control command change and the feedback deviation change according to a discrete incremental control law are as follows:

[0015] The proportional coefficient, integral coefficient, and derivative coefficient are determined based on the historical feedback deviation changes.

[0016] The control output adjustment is calculated using the proportional coefficient, integral coefficient, derivative coefficient, change in control command, and change in feedback deviation.

[0017] As a preferred embodiment of the fault early warning method for the advertising printing equipment described in this invention, the specific steps of using a gating health memory mechanism to selectively accumulate the instantaneous control margin consumption are as follows:

[0018] Collect the operating speed and tension setting values ​​of the advertising printing equipment, take the difference between adjacent operating speeds as the operating speed change, and take the difference between adjacent tension setting values ​​as the tension change.

[0019] Speed ​​and tension thresholds are set based on historical changes in operating speed and historical changes in tension.

[0020] When the change in operating speed does not exceed the speed threshold and the change in tension does not exceed the tension threshold, the operating condition is considered stable.

[0021] Arrange the instantaneous control margin consumption in chronological order and determine the temporal evolution characteristics of the instantaneous control margin consumption;

[0022] When the operating conditions are stable, the gating health memory mechanism filters and accumulates the instantaneous control margin consumption based on the time evolution characteristics to obtain a health index.

[0023] As a preferred embodiment of the fault early warning method for the advertising printing equipment of the present invention, the specific steps for determining the time evolution characteristics of the instantaneous control margin consumption are as follows:

[0024] The difference between the instantaneous control margin consumption at each moment and the instantaneous control margin consumption at the previous moment is taken as the change in control margin consumption.

[0025] When the change in control margin consumption is non-negative within a preset time window, the time evolution characteristic is determined to be a continuous evolution characteristic.

[0026] When the change in control margin consumption is not entirely non-negative within a preset time window, the time evolution characteristic is determined to be a short-term fluctuation characteristic.

[0027] In a preferred embodiment of the fault early warning method for the advertising printing equipment described in this invention, the health index is obtained by accumulating the instantaneous control margin consumption corresponding to the continuous evolution characteristics to obtain the degradation accumulation, and mapping the degradation accumulation.

[0028] In a preferred embodiment of the fault early warning method for the advertising printing equipment described in this invention, the method of using a health index to calculate the evolution rate of the equipment's health status refers to calculating the difference between the health index at the previous moment and the health index at the current moment, obtaining the range of change in the health index, and using the ratio of the range of change in the health index to the health index at the previous moment as the evolution rate.

[0029] As a preferred embodiment of the fault early warning method for advertising printing equipment described in this invention, the method for calculating the available health time window of the advertising printing equipment refers to setting a health critical index based on historical health indices, using the difference between the current health index and the health critical index as the health margin, and using the ratio of the health margin to the evolution rate as the available health time window.

[0030] As a preferred embodiment of the fault early warning method for advertising printing equipment according to the present invention, the specific steps for dividing the advertising printing equipment into any one of the following health levels—normal, attention, warning, and critical—based on the available health time window are as follows:

[0031] Set attention thresholds, warning thresholds, and critical thresholds based on historical available health time windows;

[0032] When the available health time window exceeds the attention threshold, the health level of the advertising printing equipment is determined to be normal;

[0033] When the available health time window exceeds the warning threshold but does not exceed the attention threshold, the health level of the advertising printing equipment is determined to be of concern.

[0034] When the available health time window exceeds the critical threshold but does not exceed the warning threshold, the health level of the advertising printing equipment is determined to be a warning.

[0035] When the available health time window does not exceed the critical threshold, the health level of the advertising printing equipment is determined to be critical.

[0036] Secondly, the present invention provides a fault early warning system for advertising printing equipment, comprising,

[0037] The evaluation module acquires the changes in control commands and feedback deviations of the advertising printing equipment, calculates the available control margin benchmark, and uses the changes in control commands and feedback deviations to calculate the current control output adjustment as the instantaneous control margin consumption.

[0038] The accumulation module uses a gated health memory mechanism to selectively accumulate the instantaneous control margin consumption to obtain a health index.

[0039] The estimation module uses a health index to calculate the rate of change in the health status of the equipment and to estimate the available health time window for the advertising printing equipment.

[0040] The early warning module divides the advertising printing equipment into any of the following health levels: normal, attention, warning, and critical, based on the available health time window. It then generates corresponding fault warning information and corresponding operation management measures based on the health level.

[0041] The beneficial effects of this invention are as follows: By constructing an available control margin benchmark through changes in control command and feedback deviation, the decay of control capability is transformed from a "deviation phenomenon" into a continuously trackable "margin consumption process," improving the interpretability and comparability of early degradation identification and realizing the quantification of control margin degradation. In addition, by selectively accumulating the consumption of continuously evolving characteristics under stable operating conditions through a gated health memory mechanism, the remaining available operating window can be quantitatively predicted, supporting the forward-looking formulation of normal, attention, early warning, and critical level early warning and corresponding operation management measures, thus solving the problem of the difficulty in predicting the available health time window. Attached Figure Description

[0042] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0043] Figure 1 A flowchart for a fault early warning method for advertising printing equipment.

[0044] Figure 2 This is a schematic diagram for calculating the instantaneous control margin consumption.

[0045] Figure 3 A schematic diagram illustrating the selective accumulation of gated health memory mechanisms.

[0046] Figure 4 This is a diagram illustrating the health level warning system. Detailed Implementation

[0047] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0048] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0049] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0050] Reference Figures 1-4 As one embodiment of the present invention, this embodiment provides a fault early warning method for advertising printing equipment, comprising the following steps:

[0051] S1: Obtain the change in control command and the change in feedback deviation of the advertising printing equipment, calculate the available control margin reference, and use the change in control command and the change in feedback deviation to calculate the current control output adjustment as the instantaneous control margin consumption.

[0052] S1.1: During the operation of the advertising printing equipment, collect the changes in the control commands of the advertising printing equipment and the corresponding changes in the feedback deviation.

[0053] The change in control command refers to the magnitude of change in the tension setting command of the advertising printing equipment, while the change in feedback deviation refers to the magnitude of change in the difference between the tension setting value and the tension setting command of the advertising printing equipment.

[0054] S1.2: Calculate the proportional coefficient, integral coefficient, and derivative coefficient using the historical feedback deviation change. The expression is as follows:

[0055] ;

[0056] ;

[0057] ;

[0058] in, This is the proportionality coefficient. This represents the average value of the historical feedback deviation changes. This represents the maximum value of the historical feedback deviation change. The integral coefficient is... This represents the total number of time indices for the historical feedback deviation changes. For time index, This represents the change in historical feedback deviation. express Changes in historical feedback bias at any given time. express Changes in historical feedback bias at any given time. For indicator functions, when When the trend of the change in the historical feedback deviation is consistent, the indicator function is 1. When the trend of changes in the historical feedback deviation is inconsistent, the indicator function is 0. This indicates the maximum magnitude of change in the historical feedback deviation. is the differential coefficient.

[0059] S1.3: The control command change and the feedback deviation change are superimposed according to the discrete incremental control law to obtain the control output adjustment, the expression of which is:

[0060] ;

[0061] in, for The amount of control output adjustment at any given time. This is the proportionality coefficient. The integral coefficient is... The differential coefficients are... for The change in feedback deviation at any given time. for The change in feedback deviation at any given time. for The amount of change in control commands at any given time.

[0062] S1.4: Calculate the control output adjustment amount at the current moment according to the steps in S1.3, collect the historical control output adjustment amounts, take the maximum value among the historical control output adjustment amounts as the limit adjustment margin, take the difference between the current control output adjustment amount and the limit adjustment margin as the available control margin reference, and take the control output adjustment amount at the current moment as the instantaneous control margin consumption amount.

[0063] It should also be noted that by calculating the available control margin benchmark from the changes in control commands and feedback deviations, and further obtaining the instantaneous control margin consumption, the attenuation of equipment control capability can be transformed from "deviation threshold triggering" into a continuous quantitative characterization of "control margin consumption," improving the interpretability and comparability of degradation identification, and providing a unified measurement basis for subsequent health assessments.

[0064] S2: Use a gated health memory mechanism to selectively accumulate the instantaneous control margin consumption to obtain a health index.

[0065] S2.1: Collect the operating speed setting value and tension setting value of the advertising printing equipment, and calculate the difference between the current operating speed setting value and the previous operating speed setting value to obtain the change in operating speed. Calculate the difference between the current tension setting value and the previous tension setting value to obtain the change in tension.

[0066] Based on historical operating speed changes, a percentile method is used to set the speed threshold. For example, the historical operating speed changes are arranged from smallest to largest, and the 90th percentile of the historical operating speed change is selected as the speed threshold. The 90th percentile is chosen because it can define the upper limit of the speed disturbance for "stable operating conditions," taking into account both the sensitivity and stability of fault prediction and health management. If the threshold is too large, the instantaneous control margin consumption under abnormal operating conditions may be incorrectly included in the health memory accumulation, weakening the sensitivity of fault prediction and health management. If the threshold is too small, it may be misjudged as an unstable operating condition, resulting in frequent filtering of instantaneous control margin consumption and reducing the health index's ability to reflect long-term degradation trends.

[0067] Based on historical tension changes, a percentile method is used to set the tension threshold. For example, historical tension changes are arranged from smallest to largest, and the 85th percentile of historical tension changes is selected as the tension threshold. The 85th percentile is chosen because it can distinguish between main process fluctuations and long-tail abnormal disturbances, reducing the probability of misjudging abnormal tension disturbances as stable operating conditions. If the threshold is too high, it may easily mask early degradation signals caused by material aging, increased friction, or abnormal tension actuators, reducing the foresight of fault prediction and health management. If the threshold is too low, the health memory mechanism will frequently suppress the accumulation of instantaneous control margin consumption, weakening the health index's ability to characterize the true degradation trend.

[0068] When the change in operating speed does not exceed the speed threshold and the change in tension does not exceed the tension threshold, the advertising printing equipment is determined to be in a stable operating condition. When the change in operating speed exceeds the speed threshold or the change in tension exceeds the tension threshold, the advertising printing equipment is determined to be in an unstable operating condition.

[0069] S2.2: Arrange the instantaneous control margin consumption in chronological order, and use the difference between adjacent instantaneous control margin consumption as the change in control margin consumption.

[0070] When the change in control margin consumption over five consecutive control cycles is non-negative, the time evolution characteristic of the instantaneous control margin consumption is determined to be a continuous evolution characteristic. When the change in control margin consumption over five consecutive control cycles is not all non-negative, the time evolution characteristic of the instantaneous control margin consumption is determined to be a short-term fluctuation characteristic.

[0071] Five consecutive control cycles were chosen because they can reflect the true degradation trend while avoiding interference from single fluctuations on fault prediction and health management results. Longer cycles may delay the identification of the degradation trend of control capabilities and reduce the timeliness of fault prediction, while shorter cycles may lead to premature accumulation of health indices and increase the risk of misjudgment in fault prediction and health management.

[0072] It should also be noted that the control cycle is the length of time it takes for the advertising printing equipment to execute one control command calculation, feedback deviation update, and control output adjustment.

[0073] When the advertising printing equipment is in a stable operating condition and the time evolution characteristic of the instantaneous control margin consumption is a continuous evolution characteristic, the corresponding instantaneous control margin consumption is accumulated to obtain the degradation accumulation.

[0074] The health index is calculated using the cumulative amount of degradation and the available control margin as benchmarks, expressed as follows:

[0075] ;

[0076] in, For health index, As a baseline for available control margin, This represents the cumulative amount of degradation.

[0077] It should also be noted that the gated health memory mechanism selectively accumulates the instantaneous control margin consumption under stable operating conditions and forms a health index, which can effectively suppress the interference of short-term operating condition fluctuations on degradation judgment, highlight the characteristics of time evolution, and improve the signal-to-noise ratio of the health index to the degradation trend.

[0078] S3: Use the health index to calculate the rate of evolution of the equipment's health status and estimate the available health time window for the advertising printing equipment.

[0079] S3.1: Based on historical health indices, a percentile method is used to set the critical health index. For example, the historical health indices are arranged from smallest to largest, and the 20th percentile historical health index is selected as the critical health index. The 20th percentile is selected because it can avoid giving a warning only when the equipment is close to failure. If it is too large, it will easily amplify the impact of short-term fluctuations on the results of fault prediction and health management, increasing the risk of misjudgment and over-warning. If it is too small, it will easily delay the identification of the continuous degradation trend of the control capability of advertising printing equipment, reducing the foresight of fault prediction and health management.

[0080] The difference between the current health index and the health index at the previous moment is used to obtain the magnitude of the change in the health index. The ratio of the magnitude of the change in the health index to the health index at the previous moment is used as the evolution rate.

[0081] The available health time window is calculated using the current health index, health criticality index, and evolution rate, as expressed by:

[0082] ;

[0083] in, For the available healthy time window, The current health index. This is a critical health index. This represents the evolution rate.

[0084] It should also be noted that when the health index at the previous moment is less than the critical health index, the ratio of the change in the health index to the critical health index is used as the evolution rate. When the evolution rate is less than or equal to zero, the available health time window at the previous moment is directly used as the available health time window at the current moment.

[0085] It should also be noted that: by calculating the evolution rate of the health status of equipment based on the health index and further estimating the available health time window of the advertising printing equipment, the health status can be expanded from a static evaluation to a dynamic quantitative prediction framework of "evolution intensity - remaining window". This provides a calculable time scale basis for maintenance timing and risk level, and enhances the foresight of early warning and the interpretability of decision-making.

[0086] S4: Based on the available health time window, the advertising printing equipment is divided into any of the following health levels: normal, attention, warning, and critical. Based on the health level, corresponding fault warning information and corresponding operation management measures are generated.

[0087] S4.1: Based on historical available health time windows, use the percentile method to set attention thresholds, warning thresholds, and critical thresholds respectively. For example, arrange the historical available health time windows from smallest to largest, select the 60th percentile historical available health time window as the attention threshold, select the 35th percentile historical available health time window as the warning threshold, and select the 15th percentile historical available health time window as the critical threshold.

[0088] The 60th percentile of historical available health time window was chosen because the 50th percentile can reflect the intermediate level of equipment health transitioning from stable to deteriorating. If it is too large, it is easy to enter a state of concern too early, amplifying the impact of normal fluctuations on fault prediction and health management. If it is too small, it is easy to ignore early signs of degradation, weakening the foresight of health management.

[0089] The 35th percentile historical available health time window was chosen because the 30th percentile historical available health time window is shorter but has not yet entered the out-of-control stage. If it is too large, it is easy to trigger warnings frequently and increase the frequency of operational intervention. If it is too small, it is easy to delay the identification of the true risk status and reduce the timeliness of fault prediction.

[0090] The 15th percentile of historical available health time window was chosen because the 15th percentile is close to uncontrollable risk. If it is too large, it is easy to enter the critical state prematurely, resulting in excessive downtime or maintenance. If it is too small, it is easy to increase the risk of failure, which is not conducive to the achievement of failure prediction and health management goals.

[0091] S4.2: Compare the current available health time window with the attention threshold, warning threshold, and critical threshold:

[0092] When the available health time window at the current moment exceeds the attention threshold, the health level of the advertising printing equipment will be judged as normal.

[0093] If the available health time window at the current moment does not exceed the attention threshold, and the available health time window at the current moment exceeds the warning threshold, the health level of the advertising printing equipment will be judged as attention.

[0094] If the available health time window at the current moment does not exceed the warning threshold, and the available health time window at the current moment exceeds the critical threshold, the health level of the advertising printing equipment will be judged as a warning.

[0095] When the available health time window at the current moment does not exceed the critical threshold, the health level of the advertising printing equipment is determined to be critical.

[0096] S4.3: When the health level of the advertising printing equipment is normal, generate a fault warning message that "the advertising printing equipment is operating normally" and continuously monitor the health index and available health time window.

[0097] When the health level of the advertising printing equipment is "attention", a fault warning message "the operating status of the advertising printing equipment needs attention" is generated, and the changes in control commands, feedback deviations, and instantaneous control margin consumption are continuously monitored.

[0098] When the health level of the advertising printing equipment is in the warning stage, a fault warning message "There is a risk in the operation of the advertising printing equipment" is generated, and maintenance personnel are notified to perform maintenance after printing is completed.

[0099] When the health level of the advertising printing equipment reaches a critical point, a fault warning message "the operation of the advertising printing equipment is close to being out of control" is generated, printing is immediately stopped, and maintenance personnel are notified to perform maintenance.

[0100] It should also be noted that: by classifying health levels as normal, attentive, warning, and critical based on available health time windows, and outputting corresponding fault warning information and corresponding operation management measures, a closed-loop mapping from "window prediction results" to "tiered intervention strategies" can be achieved, improving the hierarchy and executability of operation management, and avoiding the risk of excessive downtime or missed alarms caused by relying solely on a single alarm.

[0101] This embodiment also provides a fault early warning system for advertising printing equipment, including:

[0102] The evaluation module acquires the changes in control commands and feedback deviations of the advertising printing equipment, calculates the available control margin benchmark, and uses the changes in control commands and feedback deviations to calculate the current control output adjustment as the instantaneous control margin consumption.

[0103] The accumulation module uses a gated health memory mechanism to selectively accumulate the instantaneous control margin consumption to obtain a health index.

[0104] The estimation module uses a health index to calculate the rate of change in the health status of the equipment and to estimate the available health time window for the advertising printing equipment.

[0105] The early warning module divides the advertising printing equipment into any of the following health levels: normal, attention, warning, and critical, based on the available health time window. It then generates corresponding fault warning information and corresponding operation management measures based on the health level.

[0106] This embodiment also provides a computer device applicable to a fault warning method for advertising printing equipment, comprising: a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to implement the fault warning method for advertising printing equipment as proposed in the above embodiment.

[0107] The computer device can be a terminal, comprising a processor, memory, communication interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, carrier networks, NFC (Near Field Communication), or other technologies. The display screen can be an LCD screen or an e-ink screen. The input devices can be a touch layer covering the display screen, buttons, a trackball, or a touchpad on the computer device's casing, or an external keyboard, touchpad, or mouse.

[0108] This embodiment also provides a storage medium storing a computer program, which, when executed by a processor, implements the fault warning method for advertising printing equipment as proposed in the above embodiments. The storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Static Random Access Memory (SRAM), Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), Programmable Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk.

[0109] In summary, this invention constructs an available control margin benchmark by combining changes in control commands and feedback deviations, transforming the decay of control capability from a "deviation phenomenon" into a continuously trackable "margin consumption process." This improves the interpretability and comparability of early degradation identification and quantifies control margin degradation. Furthermore, by using a gated health memory mechanism to selectively accumulate the consumption of continuously evolving characteristics under stable operating conditions, it achieves quantitative prediction of the remaining available operating window and supports the forward-looking formulation of normal, watch, early warning, and critical level early warnings and corresponding operation management measures, thus solving the problem of the difficulty in predicting the available health time window.

[0110] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A fault early warning method for advertising printing equipment, characterized in that: include, Obtain the change in control command and the change in feedback deviation of the advertising printing equipment, calculate the available control margin reference, and use the change in control command and the change in feedback deviation to calculate the current control output adjustment as the instantaneous control margin consumption. A health index is obtained by selectively accumulating the instantaneous control margin consumption using a gated health memory mechanism. The health index is used to calculate the rate of change in the health status of the equipment and to estimate the available health time window for the advertising printing equipment. Based on the available health time window, the advertising printing equipment is divided into any of the following health levels: normal, attention, warning, and critical. Corresponding fault warning information and corresponding operation management measures are generated according to the health level.

2. The fault early warning method for advertising printing equipment as described in claim 1, characterized in that: The calculation can be performed using a control margin benchmark, and the specific steps are as follows: The control output adjustment is obtained by superimposing the change in control command and the change in feedback deviation according to the discrete incremental control law. The limit adjustment margin is set based on the historical control output adjustment, and the available control margin benchmark is calculated using the control output adjustment and the limit adjustment margin.

3. The fault early warning method for advertising printing equipment as described in claim 2, characterized in that: The specific steps for superimposing the control command change and the feedback deviation change using a discrete incremental control law are as follows: The proportional coefficient, integral coefficient, and derivative coefficient are determined based on the historical feedback deviation changes. The control output adjustment is calculated using the proportional coefficient, integral coefficient, derivative coefficient, change in control command, and change in feedback deviation.

4. The fault early warning method for advertising printing equipment as described in claim 1, characterized in that: The specific steps for selectively accumulating instantaneous control margin consumption using a gated health memory mechanism are as follows: Collect the operating speed and tension setting values ​​of the advertising printing equipment, take the difference between adjacent operating speeds as the operating speed change, and take the difference between adjacent tension setting values ​​as the tension change. Speed ​​and tension thresholds are set based on historical changes in operating speed and historical changes in tension. When the change in operating speed does not exceed the speed threshold and the change in tension does not exceed the tension threshold, the operating condition is considered stable. Arrange the instantaneous control margin consumption in chronological order and determine the temporal evolution characteristics of the instantaneous control margin consumption; When the operating conditions are stable, the gating health memory mechanism filters and accumulates the instantaneous control margin consumption based on the time evolution characteristics to obtain a health index.

5. The fault early warning method for advertising printing equipment as described in claim 4, characterized in that: The specific steps for determining the time evolution characteristics of instantaneous control margin consumption are as follows: The difference between the instantaneous control margin consumption at each moment and the instantaneous control margin consumption at the previous moment is taken as the change in control margin consumption. When the change in control margin consumption is non-negative within a preset time window, the time evolution characteristic is determined to be a continuous evolution characteristic. When the change in control margin consumption is not entirely non-negative within a preset time window, the time evolution characteristic is determined to be a short-term fluctuation characteristic.

6. The fault early warning method for advertising printing equipment as described in claim 4, characterized in that: The health index is obtained by accumulating the instantaneous control margin consumption corresponding to the continuous evolution characteristics to obtain the cumulative degradation amount, and then mapping the cumulative degradation amount.

7. The fault early warning method for advertising printing equipment as described in claim 1, characterized in that: The method of using the health index to calculate the evolution rate of the device's health status refers to calculating the difference between the health index at the previous moment and the health index at the current moment, obtaining the magnitude of the change in the health index, and using the ratio of the magnitude of the change in the health index to the health index at the previous moment as the evolution rate.

8. The fault early warning method for advertising printing equipment as described in claim 1, characterized in that: The estimated available health time window for advertising printing equipment refers to setting a health threshold index based on historical health indices, using the difference between the current health index and the health threshold index as the health margin, and the ratio of the health margin to the evolution rate as the available health time window.

9. The fault early warning method for advertising printing equipment as described in claim 1, characterized in that: The specific steps for classifying advertising printing equipment into any of the following health levels—normal, attention, warning, and critical—based on available health time windows are as follows: Set attention thresholds, warning thresholds, and critical thresholds based on historical available health time windows; When the available health time window exceeds the attention threshold, the health level of the advertising printing equipment is determined to be normal; When the available health time window exceeds the warning threshold but does not exceed the attention threshold, the health level of the advertising printing equipment is determined to be of concern. When the available health time window exceeds the critical threshold but does not exceed the warning threshold, the health level of the advertising printing equipment is determined to be a warning. When the available health time window does not exceed the critical threshold, the health level of the advertising printing equipment is determined to be critical.

10. A fault early warning system for advertising printing equipment, based on the fault early warning method for advertising printing equipment according to any one of claims 1 to 9, characterized in that: include, The evaluation module acquires the changes in control commands and feedback deviations of the advertising printing equipment, calculates the available control margin benchmark, and uses the changes in control commands and feedback deviations to calculate the current control output adjustment as the instantaneous control margin consumption. The accumulation module uses a gated health memory mechanism to selectively accumulate the instantaneous control margin consumption to obtain a health index. The estimation module uses a health index to calculate the rate of change in the health status of the equipment and to estimate the available health time window for the advertising printing equipment. The early warning module divides the advertising printing equipment into any of the following health levels: normal, attention, warning, and critical, based on the available health time window. It then generates corresponding fault warning information and corresponding operation management measures based on the health level.

Images