Lubricant oil diagnosis system

Abstract

To provide a lubricating oil diagnosis system which suppresses increase of time and effort for collecting lubricating oil from a machine having a lubrication portion (lubrication-target machine) and suppresses reduction of an amount of the lubricating oil in the lubrication-target machine, and furthermore can detect abnormality of the lubricating oil.SOLUTION: A lubricating oil diagnosis system 100 diagnosing a deteriorated state of lubricating oil on the basis of the analysis result of the lubricating oil comprises: a server 200 receiving the analysis result. The server 200 selects an analysis item in which a value exceeds a prescribed threshold indicating a symptom of the abnormality out of the analysis items included in the analysis result, as an analysis item which requires monitoring, selects a sensor measurement item capable of detecting deterioration or a pollution phenomenon of oil corresponding to the analysis item which requires monitoring, then selects a sensor kit which can measure the sensor measurement item, as a monitoring sensor kit for monitoring the deterioration or pollution phenomenon of the oil, out of a plurality of kinds of sensor kits, and then outputs information related to the monitoring sensor kit.SELECTED DRAWING: Figure 10

Description

[Technical field]

[0001] The present invention relates to a system for diagnosing the deterioration state of a lubricating oil. [Background technology]

[0002] Hydraulic excavators and other work machines use lubricants such as hydraulic oil and engine oil. Lubricants deteriorate depending on how the work machine is used, and their lubricating performance declines. Since the condition of this lubricant affects all the parts in the oil circuit of the work machine, it is important to properly manage the condition of the lubricant in order to keep the work machine healthy over the long term. For this reason, lubricant is regularly sampled from the work machine and analyzed to diagnose the deterioration state of the lubricant.

[0003] Patent Document 1 discloses a construction machinery management system that uses the test results of oil sampled from the construction machinery to diagnose the condition of the construction machinery and its components. Patent Document 2 discloses a work machinery diagnostic system that can accurately determine whether or not detailed oil analysis involving oil sampling is necessary. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6329892 [Patent Document 2] Patent No. 6234359 Summary of the Invention [Problem to be solved by the invention]

[0005] In both the construction machinery management system described in Patent Document 1 and the work machinery diagnostic system described in Patent Document 2, it is necessary to sample lubricant oil from the work machinery in order to detect abnormalities in the lubricant oil. Therefore, if an indication of abnormality is found in the analysis results, it is necessary to shorten the analysis interval of the lubricant oil thereafter so that the abnormality in the lubricant oil can be detected promptly. However, if the frequency of sampling the lubricant oil increases, the labor required for sampling increases and the amount of lubricant oil lost in the work machinery increases, making it operationally difficult to shorten the analysis interval.

[0006] The present invention has been made in consideration of the above-mentioned problems, and its purpose is to provide a lubricant diagnosis system that can detect abnormalities in a lubricant while suppressing an increase in the effort required to collect lubricant from a machine having a lubricated part (a machine to be lubricated) and a decrease in the amount of lubricant in the machine to be lubricated. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, the present invention provides a lubricant diagnostic system that diagnoses the deterioration state of a lubricant based on the analysis results of the lubricant, and includes a server that receives the analysis results, and the server selects, from among the analysis items included in the analysis results, analysis items that exceed a predetermined threshold indicating signs of abnormality as analysis items requiring monitoring, selects sensor measurement items capable of detecting oil deterioration or contamination phenomena corresponding to the analysis items requiring monitoring, selects, from among multiple types of sensor kits, those capable of measuring the sensor measurement items as monitoring sensor kits for monitoring the oil deterioration or contamination phenomena, and outputs information regarding the monitoring sensor kits. Effect of the Invention

[0008] According to the present invention, when an indication of an abnormality is found in the analysis results of the lubricant collected from the lubricated machine, information on the monitoring sensor kit capable of detecting the abnormality can be obtained. By attaching this monitoring sensor kit to the lubricated machine, it becomes possible to detect an abnormality in the lubricant with the monitoring sensor kit without subsequently collecting and analyzing the lubricant. This makes it possible to detect an abnormality in the lubricant while suppressing an increase in the effort of collecting the lubricant from the lubricated machine and a decrease in the amount of lubricant in the lubricated machine. [Brief description of the drawings]

[0009] [Figure 1] 1 is a diagram showing a configuration of a lubricant oil diagnosis system according to an embodiment of the present invention. [Diagram 2] FIG. 4 is a diagram showing the relationship between the operating time of a work machine and values ​​of oil analysis items in the embodiment of the present invention. [Diagram 3] FIG. 2 is a functional block diagram of a manufacturer's computer according to the embodiment of the present invention. [Figure 4] FIG. 4 is a diagram showing an example of information stored in an oil analysis item database according to the embodiment of the present invention. [Diagram 5] FIG. 4 is a diagram showing an example of information stored in an oil sensor measurement item database in the embodiment of the present invention. [Figure 6] FIG. 4 is a diagram showing an example of information stored in an oil sensor kit database in the embodiment of the present invention. [Figure 7] FIG. 11 is a diagram showing an example of information stored in a multiple sensor kit database according to the embodiment of the present invention. [Figure 8] FIG. 11 is a diagram showing an example of information stored in a sensor kit inventory database according to the embodiment of the present invention. [Figure 9] FIG. 4 is a diagram showing an example of information stored in a transportation information database according to an embodiment of the present invention. [Figure 10] 4 is a flowchart showing a process of a computer for an oil manufacturer according to an embodiment of the present invention. [Figure 11] 11 is a diagram showing an example of an output of a sensor kit candidate when a Karl Fischer test, which is one of the oil analysis items included in the oil analysis result in the embodiment of the present invention, is judged to be at a caution level. FIG. [Figure 12] FIG. 13 is a diagram showing an example of an output of a sensor kit candidate when the degree of contamination (counting method), which is one of the oil analysis items included in the oil analysis result in the embodiment of the present invention, is determined to be at a caution level. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In each drawing, the same reference numerals are used for equivalent members, and duplicated explanations will be omitted as appropriate. In the embodiment of the present invention, a work machine such as a hydraulic excavator will be described as an example of a machine having a lubricated portion (a machine to be lubricated), but the machine to be lubricated is not limited to a work machine.

[0011] 1 is a diagram showing the configuration of a lubricant diagnostic system in this embodiment. The lubricant diagnostic system 100 includes a manufacturer's computer 200 consisting of a server owned by a work machine manufacturer that manufactures a work machine 101 such as a hydraulic excavator, a central warehouse computer 103 that manages the inventory of parts and the like for the work machine 101, an analysis company's computer 104 owned by an oil analysis company that analyzes lubricants (hydraulic oil, engine oil, etc.) collected from the work machine 101, a manager's computer 105 owned by a user of the work machine 101, and a service computer 106 owned by an agency or the like of the work machine manufacturer. The manufacturer's computer 200 exchanges information with the central warehouse computer 103, the analysis company's computer 104, the manager's computer 105, and the service computer 106 via communication means such as the Internet.

[0012] Lubricating oil (hydraulic oil, engine oil, etc.) is periodically sampled from the work machine 101, and the sampled lubricating oil is sent to an oil analysis company. The oil analysis company analyzes the sampled lubricating oil, and transmits the analysis results from the analysis company's computer 104 to the manufacturer's computer 200. The manufacturer's computer 200 performs a diagnosis using the analysis results received from the analysis company's computer 104, and transmits the diagnosis results to the manager's computer 105 and the service computer. In addition, the manufacturer's computer 200 inquires about inventory and places an order for a sensor kit (described later) with the central warehouse computer 103 based on the lubricating oil diagnosis results.

[0013] FIG. 2 is a diagram showing the relationship between the operating time of the work machine 101 and the value of an oil analysis item. The value of the oil analysis item changes as the deterioration or contamination of the oil progresses according to the operating time of the work machine 101. For the oil analysis item, a caution value is set as a threshold value indicating a sign of abnormality, and an abnormal value is set as a threshold value indicating abnormality. When the value of the oil analysis item is equal to or greater than the abnormal value (upper limit), or equal to or less than the abnormal value (upper limit), the oil analysis item is determined to be at an abnormal level. When the value of the oil analysis item is less than the abnormal value (upper limit) and equal to or greater than the caution value (upper limit), or greater than the abnormal value (lower limit) and less than the caution value (lower limit), the oil analysis item is determined to be at a caution level. When the value of the oil analysis item is less than the caution value (upper limit) and greater than the caution value (lower limit), the oil analysis item is determined to be at a normal level. The manufacturer's computer 200 manages the values ​​of the oil analysis items by linking them to the type of oil (hydraulic oil, engine oil, etc.) and model information of the work machine 101.

[0014] 3 is a functional block diagram of the manufacturer's computer 200. The processing unit 201 of the manufacturer's computer 200 has an oil analysis result determination unit 202 that determines whether an oil analysis item is at a caution level or an abnormal level, a sensor kit selection unit 203 that selects a sensor kit capable of detecting oil deterioration or contamination phenomena corresponding to an oil analysis item determined to be at a caution level, and an inventory information calculation unit 204 that calculates sensor kits that can be procured and price information from sensor kit inventory information and transportation information. The sensor kit consists of a sensor and an accessory part for attaching the sensor to a corresponding location on the work machine 101.

[0015] The storage unit 210 of the manufacturer's computer 200 has an oil analysis item database (hereinafter abbreviated as DB) 211, an oil sensor measurement item DB 212, an oil sensor kit DB 213, a different type sensor kit DB 214, a sensor kit inventory DB 215, and a transportation information DB216.

[0016] FIG. 4 is a diagram showing an example of information stored in the oil analysis item DB 211. The oil analysis item DB 211 stores information on oil deterioration or contamination phenomena, oil analysis items (items (standards) of oil analysis methods for oil deterioration or contamination phenomena), and judgment values ​​(caution values ​​and abnormal values) for the oil analysis items. Oxidation is an example of oil deterioration. When oxidation progresses with use of oil, oxidation products are generated, which may lead to deterioration of sliding performance and damage to mechanical sliding parts. Examples of oil contamination phenomena include the inclusion of moisture, sand, dust, wear powder, fuel, soot, coolant, etc. When liquids such as moisture, fuel, and coolant are mixed into oil, seizure of the sliding parts of mechanical parts may occur due to a decrease in viscosity, and when moisture is mixed in, rust may occur. When hard particles such as sand, dust, wear powder, and soot (a by-product generated during combustion) are mixed into oil, these particles may cause wear of mechanical sliding parts. For example, analytical methods for oxidation include total acid number (JIS K2501), contamination level (mass method) (JIS B9931), contamination level (counting method) (ISO 4406), color (ASTM D1500), and FTIR (ASTM E2412). Note that the descriptions of the judgment values ​​are simplified in Figure 4, but in the case of elemental analysis (ASTM D5185), for example, judgment values ​​are set for each element to be analyzed, such as iron, copper, lead, chromium, and nickel.

[0017] 5 is a diagram showing an example of information stored in the oil sensor measurement item DB 212. Information on oil sensor measurement items that are sensitive to oil deterioration or contamination phenomena is stored in the oil sensor measurement item DB 212. For example, oil sensor measurement items that are sensitive to oxidation include color, particles, density, and dielectric constant.

[0018] FIG. 6 is a diagram showing an example of information stored in the oil sensor kit DB 213. The oil sensor kit DB 213 stores information on the sensor measurement items of each oil sensor kit. As the sensor kit A whose sensor measurement item is color, there is a sensor kit that measures light transmitted through oil with an RGB sensor. As the sensor kit E whose oil sensor measurement items are viscosity, density, and dielectric constant, there is a sensor kit that measures viscosity, density, and dielectric constant by utilizing the frequency characteristics of a tuning fork. Note that the oil deterioration or contamination phenomenon, oil analysis items, oil sensor measurement items, and oil sensor kits are not limited to those exemplified in FIGS. 4 to 6.

[0019] FIG. 7 is a diagram showing an example of information stored in the other sensor kit DB 214. The other sensor kit DB 214 stores information on oil deterioration or contamination phenomenon, oil analysis items, the model of the work machine 101, the type of oil, specific parts, measurement items, and other sensor kits (sensor kits other than oil sensor kits). It is possible to estimate that there is an abnormality in a specific part of the work machine 101 from the oil deterioration or contamination phenomenon, the oil analysis items exceeding the caution value, the model of the work machine 101, and the type of oil. Examples of specific parts include the main pump, engine, hydraulic cylinder, swing device, and traveling device. There are sensor kits that can be attached to these specific parts to directly monitor the state of the specific parts. For example, when wear powder Cu is detected in the hydraulic oil of the work machine 101, it is possible that the main pump members are worn, so it is possible to detect the abnormality by attaching a vibration sensor kit that detects vibration to the main pump. When wear powder Cr is detected in the engine oil of the work machine 101, it is possible that the engine members are worn, so it is possible to detect the abnormality by attaching a vibration sensor kit to the engine. In addition, examples of other types of sensor kits include sensor kits that detect images, sounds, and pressures in addition to vibration sensor kits.

[0020] 8 is a diagram showing an example of information stored in the sensor kit inventory DB 215. The sensor kit inventory DB 215 stores information on the items, quantities, and prices of sensor kits stored at each base.

[0021] 9 is a diagram showing an example of information stored in the transport information DB 216. Information on the sensor kit item, supply base, ordering base, supply means, transport lead time, and transport cost is stored in the transport information DB 216. The information in the transport information DB 216 is used to calculate the transport means, delivery date, and price from the reception date and order location information (the base nearest to the work machine 101) when a sensor kit candidate for an oil deterioration or contamination phenomenon is output.

[0022] 10 is a flowchart showing the processing of the manufacturer's computer 200. When the oil analysis result determination unit 202 receives the oil analysis result from the analysis company's computer 104, it acquires the judgment values ​​(caution values ​​and abnormal values) of the oil analysis items from the oil analysis item DB 211 (step S1).

[0023] Following step S1, it is determined whether all the oil analysis items included in the oil analysis result are below the caution value (step S2).

[0024] If the determination result in step S2 is Yes, the lubricant is determined to be normal (step S3), and the flow ends.

[0025] If the determination result in step S2 is No, it is determined whether or not any of the oil analysis items included in the oil analysis results has an abnormal value or higher (step S4).

[0026] If the determination result in step S4 is Yes, it is determined that the lubricant is abnormal (step S5).

[0027] Following step S5, a notice is given that maintenance is necessary (step S6), and the flow ends.

[0028] If the determination result in step S4 is No, the sensor kit selection unit 203 refers to the oil sensor measurement item DB 212 and selects an oil sensor measurement item that can detect oil deterioration or contamination phenomena corresponding to an oil analysis item that exceeds the caution value (step S7).

[0029] Following step S7, the oil sensor kit DB 213 is referenced and oil sensor kits capable of measuring the oil sensor measurement items are selected as oil sensor kit candidates (step S8).

[0030] Following step S8, the other sensor kit DB 214 is referenced and other sensor kits corresponding to the oil deterioration or contamination phenomenon, oil analysis items, model of the work machine 101, and type of oil are selected as other sensor kit candidates (step S9).

[0031] Following step S9, the inventory information calculation unit 204 refers to the sensor kit inventory DB 215 and the transport information DB 216, and calculates the delivery date and price of each sensor kit candidate (step S10). Specifically, it checks the inventory of the sensor kit candidate at the base closest to the work machine 101 where the oil analysis was performed, and if there is no inventory, it checks the inventory at the base closest to the supply base, calculates the price and delivery date of the sensor kit candidate, outputs the sensor kit candidates to be displayed in order of lowest price, and notifies the user, the agency, etc.

[0032] Following step S10, it is determined whether the notified sensor kit candidate has been selected (step S11).

[0033] If the determination result in step S11 is Yes, the selected sensor kit is arranged (step S12), and the flow ends.

[0034] If the result of the determination in step S11 is No, the timing when the oil analysis item that has reached the caution value is expected to reach an abnormal value is notified as the timing of the next oil analysis (step S12), and the flow ends. The timing when the oil analysis item is expected to reach an abnormal value is found by linearly interpolating the value of the oil analysis item against the operating time (shown in FIG. 2).

[0035] FIG. 11 is a diagram showing an example of output of sensor kit candidates when the Karl Fischer test, which is one of the oil analysis items included in the oil analysis result, is at the caution level. The manufacturer's computer 200 selects water contamination from the oil analysis item DB 211 as an oil deterioration or contamination phenomenon corresponding to the Karl Fischer test. From the oil sensor measurement item DB 212, the manufacturer's computer 200 selects dielectric constant and electrical conductivity as the oil sensor measurement items corresponding to water contamination. From the oil sensor kit DB 213, the manufacturer's computer 200 selects sensor kits B, E, F, and G as oil sensor kit candidates corresponding to the dielectric constant and electrical conductivity of the oil sensor measurement items. Note that, since information on other types of sensor kits corresponding to water contamination and the Karl Fischer test, which is an oil analysis item, is not stored in the other types of sensor kit DB 214, the other types of sensor kit candidates are not selected. Next, the manufacturer's computer 200 checks the inventory of the sensor kit candidates at the base closest to the work machine 101 where the oil analysis was performed. If there is no inventory, the manufacturer's computer 200 checks the inventory at the base closest to the supply base. The manufacturer's computer 200 calculates the price and delivery time of the sensor kit, and displays the oil sensor kits in order of lowest price. When a sensor kit candidate is selected, the selected sensor kit candidate is arranged.

[0036] FIG. 12 is a diagram showing an example of an output of sensor kit candidates when the pollution level (counting method), which is one of the oil analysis items included in the oil analysis result, is judged to be at the caution level. The manufacturer's computer 200 selects oxidation and wear debris contamination as oil deterioration or contamination phenomena corresponding to the pollution level (counting method) from the oil analysis item DB 211. The component of wear debris is iron. As the oil sensor measurement items corresponding to oxidation, color, particles, density, and dielectric constant are selected from the oil sensor measurement item DB 212. Similarly, as the oil sensor measurement items corresponding to wear debris contamination, particles, conductivity, and magnetic change are selected. As the oil sensor kits corresponding to oxidation (oil sensor measurement items color, particles, density, and dielectric constant), sensor kits A, B, D, E, F, G, and H are selected from the oil sensor kit DB 213. Similarly, sensor kits G, H, and I are selected as the oil sensor kits corresponding to wear debris contamination (oil sensor measurement items particles, conductivity, and magnetic change). Note that, since information on other types of sensor kits corresponding to the oxidation or wear powder contamination and the pollution level (counting method) of the oil analysis items is not stored in the other types of sensor kit DB 214, other types of sensor kit candidates are not selected. Next, the inventory of the sensor kit candidates at the base closest to the work machine 101 where the oil analysis was performed is checked. If there is no inventory, the inventory of the base closest to the supply base is checked. The price and delivery time of the sensor kit are calculated, and the sensor kits are displayed in order of lowest price for each oil deterioration or pollution phenomenon. If a sensor kit candidate is selected, the selected sensor kit candidate is arranged.

[0037] (summary) In this embodiment, a lubricant diagnostic system 100 that diagnoses the deterioration state of a lubricant based on the analysis results of the lubricant is provided with a server 200 that receives the analysis results, and the server 200 selects, from among the analysis items included in the analysis results, analysis items that exceed a predetermined threshold indicating signs of abnormality as analysis items requiring monitoring, selects sensor measurement items capable of detecting oil deterioration or contamination phenomena corresponding to the analysis items requiring monitoring, selects, from among multiple types of sensor kits, those capable of measuring the sensor measurement items as monitoring sensor kits for monitoring the oil deterioration or contamination phenomena, and outputs information regarding the monitoring sensor kits.

[0038] According to this embodiment configured as described above, when an indication of an abnormality is found in the analysis results of the lubricant oil sampled from the work machine 101, information from the monitoring sensor kit capable of detecting the abnormality can be obtained. By attaching this monitoring sensor kit to the work machine 101, it becomes possible to detect an abnormality in the lubricant oil with the monitoring sensor kit without subsequently sampling and analyzing the lubricant oil. This makes it possible to detect an abnormality in the lubricant oil while suppressing an increase in the effort of sampling the lubricant oil from the work machine 101 and a decrease in the amount of lubricant oil in the work machine 101.

[0039] In the present embodiment, the oil deterioration or contamination phenomenon includes one or more of oxidation, water contamination, sand and dust contamination, wear powder contamination, fuel contamination, soot contamination, and coolant contamination. This makes it possible to detect oil deterioration or contamination caused by any of viscosity increase, oxidation, water contamination, sand and dust contamination, wear powder contamination, fuel contamination, soot contamination, and coolant.

[0040] In addition, the sensor measurement items in this embodiment include one or more of color, particles, viscosity, density, dielectric constant, conductivity, and magnetic change. This makes it possible to detect oil deterioration or contamination phenomena by measuring any one of color, particles, viscosity, density, dielectric constant, conductivity, and magnetic change.

[0041] Furthermore, the sensor measurement items in this embodiment include one or more of vibration, pressure, sound, and image associated with the oil deterioration or contamination phenomenon, the model of the work machine 101, the type of the lubricating oil, and the part of the equipment mounted on the work machine 101. This makes it possible to detect the oil deterioration or contamination phenomenon by measuring any of the vibration, pressure, sound, and image.

[0042] Although the embodiment of the present invention has been described above in detail, the present invention is not limited to the above-mentioned embodiment and includes various modified examples. For example, the above-mentioned embodiment has been described in detail to easily explain the present invention, and the present invention is not necessarily limited to an embodiment having all of the described configurations. [Explanation of symbols]

[0043] 100...lubricant diagnostic system, 101...work machine, 103...central warehouse computer, 104...analysis company computer, 105...administrator computer, 106...service computer, 200...manufacturer computer (server), 201...processing unit, 202...oil analysis result determination unit, 203...sensor kit selection unit, 204...inventory information calculation unit, 210...memory unit, 211...oil analysis item DB, 211...oil analysis item DB, 212...oil sensor measurement item DB, 213...oil sensor kit DB, 214...other types of sensor kit DB, 215...sensor kit inventory DB, 216...transportation information DB.

Claims

1. In a lubricant diagnostic system that diagnoses the deterioration state of the lubricant based on the analysis results of the lubricant, The system includes a server that receives the aforementioned analysis results, The aforementioned server, Among the analysis items included in the above analysis results, analysis items that exceed a predetermined threshold indicating an abnormality are selected as items requiring monitoring. Select sensor measurement items that can detect oil deterioration or contamination phenomena corresponding to the aforementioned items requiring monitoring and analysis, From among several types of sensor kits, those capable of measuring the aforementioned sensor measurement items are selected as monitoring sensor kits for monitoring the deterioration or contamination phenomenon of the oil. Outputs information regarding the aforementioned monitoring sensor kit. A lubricant diagnostic system characterized by the following features.

2. In the lubrication oil diagnostic system according to claim 1, The aforementioned oil deterioration or contamination phenomena include one or more of the following: oxidation, water contamination, sand and dust contamination, wear particle contamination, fuel contamination, soot contamination, and coolant contamination. A lubricant diagnostic system characterized by the following features.

3. In the lubrication oil diagnostic system according to claim 1, The sensor measurement items include one or more of the following: color, particles, viscosity, density, dielectric constant, conductivity, and magnetic change. A lubricant diagnostic system characterized by the following features.

4. In the lubrication oil diagnostic system according to claim 1, The sensor measurement items include one or more vibrations, pressures, sounds, and images associated with the deterioration or contamination of the oil, the model of the work machine, the type of lubricating oil, and the parts of the equipment mounted on the work machine. A lubricant diagnostic system characterized by the following features.

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