Machine evaluation system and machine evaluation method

Abstract

To evaluate the state of an industrial machine with high precision.SOLUTION: A machine evaluation system comprises an operation history storage part which stores a history of operations of an industrial machine, a maintenance history storage part which stores a history of maintenance operations on the industrial machine, and an evaluation part which evaluates the state of the industrial machine based upon the history of operations and the history of maintenance operations, and the evaluation part outputs use of the industrial machine after its recovery as a result of the evaluation.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a machine evaluation system and a machine evaluation method. [Background technology]

[0002] Japanese Patent Laid-Open Publication No. 2014-153736 (Patent Document 1) describes a technology for remotely monitoring a target device. This publication states that "in failure sign detection, it is possible to determine failure signs using a threshold value according to the operating status of the monitored target." and "The failure sign detection device 1 classifies monitoring data of the monitored target 2 for a period in which no abnormality was detected in the monitored target 2 by day of the week, time period, date, or number of weeks and stores the data in a storage unit (23) (14), sets an acceptable range based on the distribution of the monitoring data stored in the storage unit by day of the week, time period, date, or number of weeks, compares the monitoring data acquired from the monitored target 2 with the acceptable range based on the distribution of the monitoring data for the day of the week, time period, date, or number of weeks to which the monitoring date and time of the monitoring data belongs, and detects a failure sign of the monitored target 2 if the monitoring data exceeds the upper or lower limit of the acceptable range (13)." [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-153736 Summary of the Invention [Problem to be solved by the invention]

[0004] The above-mentioned prior art can detect a symptom of a failure in a target device, but does not take into consideration the disposal of the target device. When industrial machinery is discarded, it is collected and disposed of by the manufacturer. If the machine is in good condition, it can be reused by undergoing appropriate maintenance and selling it as second-hand equipment. Even if the entire machine cannot be used, there are cases where parts in good condition can be attached to other equipment and put to good use. In order to determine how to dispose of recovered industrial machinery, it is necessary to evaluate the condition of the industrial machinery with high accuracy. Therefore, an object of the present invention is to provide a highly accurate evaluation of the state of industrial machinery. [Means for solving the problem]

[0005] In order to achieve the above-mentioned object, one representative machine evaluation system of the present invention comprises an operation history accumulation unit that accumulates the operation history of industrial machinery, a maintenance history accumulation unit that accumulates the history of maintenance work on the industrial machinery, and an evaluation unit that evaluates the condition of the industrial machinery based on the operation history and the maintenance work history, and is characterized in that the evaluation unit outputs, as a result of the evaluation, the use of the industrial machinery after it is recovered. Furthermore, one representative machine evaluation method of the present invention is characterized in that it includes the steps of: a computer acquiring an operation history of an industrial machine to be evaluated; acquiring a maintenance work history of the industrial machine; evaluating the condition of the industrial machine based on the operation history and the maintenance work history; and outputting, as a result of the evaluation, the use of the industrial machine after it is recovered. [Effects of the Invention]

[0006] According to the present invention, the state of industrial machinery can be evaluated with high accuracy. Problems, configurations, and effects other than those described above will become apparent from the following description of the embodiments. [Brief explanation of the drawings]

[0007] [Figure 1] Illustrative diagram of mechanical evaluation in Example 1 [Figure 2] Configuration diagram of a machine evaluation system according to the first embodiment [Figure 3] Server configuration diagram [Figure 4] Examples of various data [Figure 5] Example of the management screen displayed on the management terminal [Figure 6] Evaluation device configuration diagram [Figure 7]1 is a flowchart showing a processing procedure of an evaluation device. [Figure 8] Explaining how the assessed value is calculated [Figure 9] Explaining how to determine use after collection DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, an embodiment will be described with reference to the drawings. [Example]

[0009] FIG. 1 is an explanatory diagram of the mechanical evaluation of Example 1. In the first embodiment, the compressor 10 is the subject of evaluation. The server 20 monitors the states of the multiple compressors 10. Specifically, the server 20 manages device management data 24a, operation history data 24b, maintenance history data 24c, abnormality history data 24d, environmental information data 24e, and the like for the multiple compressors 10.

[0010] The device management data 24a is data for managing the device ID that identifies the compressor 10 in association with the installation location, user, etc. The operation history data 24b is data in which operation information acquired from the compressor 10 is stored in association with the device ID. The maintenance history data 24c is data in which maintenance work performed on the compressor 10 is associated with a device ID and stored. The abnormality history data 24d is data in which abnormalities that have occurred in the compressor 10 are associated with device IDs and stored. The environmental information data 24e is data in which the operating environment of the compressor 10 is associated with the device ID and stored.

[0011] The evaluation unit 33b of the evaluation device 30 evaluates the state of the compressor 10 using various data from the server 20. The evaluation unit 33b outputs an assessed amount and a use as the evaluation results. The assessed amount indicates the value of the compressor 10 as a monetary amount. The use indicates the use of the compressor 10 after it is collected.

[0012] Uses include first reuse (reuse after performance improvement), which involves changing the configuration (remanufacturing) to provide higher performance than the original state and then using it again; second reuse (reuse after overhaul), which involves overhauling it to return it to a state close to the original state and then using it again; third reuse (reuse after maintenance), which involves performing minimal maintenance to make it operational and then using it again; and third reuse (reuse after maintenance), which involves disassembling it and using the parts individually.

[0013] The evaluation unit 33b evaluates that the first reuse (reuse after performance upgrade) can be either sold or provided on a subscription basis, the second reuse (reuse after overhaul) can be provided on a subscription basis, and the third reuse (reuse after maintenance) can be sold.

[0014] In this way, the evaluation device 30 can accurately evaluate the state of the compressor 10 and suggest appropriate uses for the compressor 10 after it has been recovered by referring to the operation and maintenance history of the compressor 10.

[0015] FIG. 2 is a configuration diagram of the machine evaluation system according to the first embodiment. A plurality of compressors 10 are purchased by users and installed in a factory L1 for use. The plurality of compressors 10 are connected to a server 20 via a network for communication and transmit information such as their operating status to the server 20. A management terminal 41 is also installed in the factory L1. The management terminal 41 is connected to the server 20 via a network. A user of the factory L1 can operate the management terminal 41 to refer to the data accumulated by the server 20. Maintenance history and the like can be sent from the management terminal 41 to the server 20.

[0016] The maintenance base L2 is a base of a company that provides maintenance services for the compressor 10. A management terminal 42 is installed at the maintenance base L2. The management terminal 42 is connected to the server 20 via a network. A maintenance technician at the maintenance base L2 can operate the management terminal 42 to refer to the data accumulated by the server 20. In addition, the maintenance history and the like can be sent from the management terminal 42 to the server 20.

[0017] The manufacturing and sales base L3 is a base of a manufacturer that manufactures and sells the compressor 10. A management terminal 43 is installed at the manufacturing and sales base L3. The management terminal 43 is connected to the server 20 via a network. A person in charge at the manufacturing and sales base L3 can operate the management terminal 43 to refer to the data accumulated by the server 20.

[0018] The evaluation device 30 may be directly connected to the server 20 or may be connected via a network. The evaluation device 30 may also be installed at the manufacturing and sales base L3.

[0019] FIG. 3 is a diagram showing the configuration of the server 20. The server 20 is a computer having a communication unit 21, a CPU (Central Processing Unit) 22, a main storage device 23, and an auxiliary storage device 24. The input and output devices are not shown or described.

[0020] The communication unit 21 is an interface for communicating with the compressor 10, the evaluation device 30, and the management terminals 41-43. The CPU 22 reads out predetermined programs from the auxiliary storage device 24 or the like, loads them into the main storage device 23, and executes them sequentially to realize various functions. The realized functions include a device management unit 23a and a data collection unit 23b.

[0021] The auxiliary storage device 24 is, for example, a hard disk drive, and stores various programs and data. The data stored in the auxiliary storage device 24 includes device management data 24a, operation history data 24b, maintenance history data 24c, abnormality history data 24d, and environmental information data 24e.

[0022] The device management unit 23a manages, as device management data 24a, information such as where each compressor 10 is installed. The data collection unit 23b acquires data relating to the operation, maintenance, abnormalities, and operating environment of the compressor 10 as needed, and manages the data by storing it in operation history data 24b, maintenance history data 24c, abnormality history data 24d, and environmental information data 24e.

[0023] Figure 4 shows specific examples of various data. The device management data 24a shown in Figure 4 associates a device ID with a model, serial number, installation location, installation date, user, and contract details. Figure 4 shows an example of a device ID "ID0001," model "M1-2," serial number "123-xxx," installation location "City A...," installation date "2019 / 10 / 09," user "U001," and contract details "maintenance contract." The user item is the identification information, name, etc. of the user who purchased or rented and uses the compressor 10. The contract details indicate the details of the contract, such as maintenance.

[0024] The operation history data 24b shown in Figure 4 associates the acquisition date and time, device ID, operating state, internal temperature, cumulative operating time, and filter state. Figure 4 shows an example of the acquisition date and time "2024 / 01 / 12 10:43:30," device ID "ID0001," operating state "unloaded," internal temperature "xx°C," cumulative operating time "3750h," and filter state "clogged." The operating state can be unloaded or in operation, for example. Furthermore, the operation information is not limited to the example shown, and can include any information. Examples include continuous operating time, load time, load count, start / stop time, suction pressure, discharge pressure, tank internal pressure, discharge temperature, and current value.

[0025] The maintenance history data 24c shown in Figure 4 associates date and time, device ID, maintenance work, maintenance result, and maintenance person. Figure 4 shows an example of date and time "2023 / 12 / 05 15:00:20", device ID "ID0001", maintenance work "regular maintenance", maintenance result "no abnormalities", and maintenance person "xx xx". Furthermore, this is not limited to an example, and any information can be included in the maintenance information.

[0026] The abnormality history data 24d shown in Figure 4 associates the date and time, device ID, abnormality content, response result, and person in charge of response. Figure 4 shows an example of the date and time "2023 / 12 / 21 11:43:50", device ID "ID0001", abnormality content "discharge pressure error 1", maintenance result "recovered", and maintenance person "yy yy". Furthermore, the data is not limited to this example, and any information related to alarms and failures can be included.

[0027] The environmental information data 24e shown in FIG. 4 associates the acquisition date and time, the device ID, and the ambient temperature. FIG. 4 shows an example in which the acquisition date and time is "2024 / 01 / 12 10:43:30," the device ID is "ID0001," and the ambient temperature is "40°C." This is not limited to the example, and any information related to the operating environment of the compressor 10 can be included. If each compressor 10 can acquire information related to the operating environment, the environmental information data 24e may be included in the operation history data 24b. If environmental information acquired by one sensor is applied to multiple compressors 10, the device ID of the environmental information data 24e may contain multiple values. In this case, an item indicating the sensor ID may be provided.

[0028] FIG. 5 is an example of a management screen displayed on the management terminal. The management terminals 41 to 43 generate a management screen using the data acquired from the server 20 and display it on the display. In Fig. 5, the device management data 24a, the operation history data 24b, the maintenance history data 24c, and the abnormality history data 24d are displayed by extracting the data of the device ID "ID0001" from the environmental information data 24e.

[0029] FIG. 6 is a diagram showing the configuration of the evaluation device 30. The evaluation device 30 is a computer having a communication unit 31, a CPU 32, a main memory device 33, and an auxiliary memory device 34. The input device and the output device are not shown and will not be described.

[0030] The communication unit 31 is an interface for communicating with the server 20 . The CPU 32 reads out a predetermined program from the auxiliary storage device 34 or the like, loads it into the main storage device 33, and executes it sequentially to realize various functions. The realized functions include a data acquisition unit 33a, an evaluation unit 33b, and an output processing unit 33c.

[0031] The data acquisition unit 33 a is a processing unit that acquires various data from the server 20 . The evaluation unit 33b uses the data acquired by the data acquisition unit 33a to evaluate the state of the compressor 10. The evaluation unit 33b outputs the assessed value and the intended use as the evaluation results. The output processing unit 33c performs a process of displaying the assessed amount and use output by the evaluation unit 33b on a display device, for example. The output processing unit 33c may also perform a process of transmitting the assessed amount and use output by the evaluation unit 33b to an external device.

[0032] 7 is a flowchart showing the processing procedure of the evaluation device 30. The evaluation device 30 sequentially executes the following steps S101 to S109. In step S101, the data acquisition unit 33a identifies the device ID of the target device. Then, the process proceeds to step S102. The target device may be a compressor 10 that has been collected from a user, or a compressor 10 that has not yet been collected and that the user has approached about purchasing.

[0033] In step S102, the data acquisition unit 33a searches the operation history data 24b of the server 20 using the device ID to acquire the operation history of the target device, and then proceeds to step S103. Step S103: The data acquisition unit 33a searches the maintenance history data 24c of the server 20 using the device ID to acquire the maintenance history of the target device, and then proceeds to step S104. Step S104: The data acquisition unit 33a searches the abnormality history data 24d of the server 20 using the device ID to acquire the abnormality history of the target device, and then proceeds to step S105. Step S105: The data acquisition unit 33a searches the environment information data 24e of the server 20 using the device ID to acquire the history of the operating environment of the target device, and then proceeds to step S106.

[0034] In step S106, the evaluation unit 33b calculates the base assessed value based on the installation date of the target device and the acquisition price at the time of installation of the target device, and then the process proceeds to step S107. In step S107, the evaluation unit 33b corrects the base assessed amount based on the operation history, maintenance history, abnormality history, operating environment, etc. of the target device, and then the process proceeds to step S108. In step S108, the evaluation unit 33b determines the use after collection based on the base assessed value, the operation history, maintenance history, abnormality history, operating environment, etc. of the target device, and then the process proceeds to step S109. In step S109, the evaluation unit 33b outputs the corrected assessed amount and use, and the process ends. The assessed amount and use output by the evaluation unit 33b are displayed or transmitted by the output processing unit 33c.

[0035] FIG. 8 is an explanatory diagram of the calculation of the assessed value. The evaluation unit 33b determines the base assessment amount by subtracting the depreciation cost from the product acquisition cost. The product acquisition cost is the cost when the user installs the target device. The depreciation cost is determined according to the number of years that have passed since the installation date.

[0036] The evaluation unit 33b multiplies the base assessed value by a coefficient according to the driving time. For example, if the driving time is 6000 hours or more, the coefficient is set to 0.5, and if the driving time is 5000 to 5999 hours, the coefficient is set to 0.6. The driving time can be obtained from the operation history.

[0037] The evaluation unit 33b multiplies the base assessed value by a coefficient according to the maintenance record. For example, if the overhaul period has passed, the coefficient is set to 1.0, and if the overhaul period is more than one year away, the coefficient is set to 1.4. The overhaul period can be determined from the maintenance record.

[0038] Furthermore, the evaluation unit 33b increases the assessed value under predetermined conditions, such as "appropriate ambient temperature," "short cumulative operating time," "low number of alarms or malfunctions," "low number of loads or load rate," "slow progress of clogging of the intake filter," and "having a maintenance contract." The evaluation unit 33b lowers the assessed value under predetermined conditions, such as "high ambient temperature," "long cumulative operating time," "high number of alarm failures," "high load count or load factor," "rapid clogging of the suction filter," "high fin / motor temperature," "no maintenance history," and "low volume of traffic." These conditions can be determined based on, for example, the operation history, maintenance history, abnormality history, and operating environment history of the target device. The presence or absence of a distribution volume can also be determined by referring to sales results separately. Although the distribution volume is not a measure of the condition of the target device itself, if there are many devices of the same model as the target device in circulation, replacement and parts acquisition will be easier, and therefore it can be used to evaluate the target device.

[0039] FIG. 9 is an explanatory diagram of determining the use after collection. New equipment is high value and reliable, making it ideal for both sales and subscriptions. Reuse after performance upgrade is the process of remanufacturing recovered equipment by modifying its configuration to provide higher performance than in its initial state. Reuse after performance upgrade has value and reliability close to that of a new product, making it suitable for both sales and subscriptions. Reuse after performance upgrade is useful in cases where environmental efforts are important. Furthermore, because it can be used for a long period of time, it is useful in cases where product replacement is difficult.

[0040] Reuse after overhaul is when recovered equipment is overhauled to return it to a state close to its original condition and then reused. Reuse after overhaul has lower value and reliability than reuse after performance improvement. If overhauled equipment were to be sold, the price difference with new equipment would be small when considering transportation and management costs, making it less appealing to users. Therefore, it is offered on a subscription basis. Providing reuse after overhaul on a subscription basis has benefits for users, such as reducing initial costs and being able to outsource management and operation. It can also provide sufficient performance for users who do not require high performance.

[0041] Reuse after maintenance is when recovered equipment is given minimal maintenance to return it to a working condition and reused. Reuse after maintenance has lower value and reliability than reuse after overhaul. Reuse after maintenance has a higher risk of failure, so it is not suitable for subscription. Therefore, it is offered for sale. Reuse after maintenance is beneficial for price-conscious users, users who will only use the equipment for a short period of time, users who wish to keep it as a spare, and users who can perform maintenance in-house.

[0042] The evaluation unit 33b calculates a reliability value from the operation history, maintenance history, abnormality history, operating environment, etc. of the target device, and plots the base assessed amount as a value on the graph of FIG. 9. If the plotted result is within the region of reuse after performance improvement, the evaluation unit 33b determines the use after recovery as reuse after performance improvement. Similarly, if the plotted result is within the region of reuse after overhaul, the evaluation unit 33b determines the use after recovery as reuse after overhaul. If the plotted result is within the region of reuse after maintenance, the evaluation unit 33b determines the use after recovery as reuse after maintenance. If the plotted result does not fall within either region, the evaluation unit 33b determines the use after recovery as parts recovery, which is disassembled and reused for individual parts.

[0043] As described above, in the machine evaluation system disclosed in the embodiments, the auxiliary storage device 24 of the server 20 functions as an operation history storage unit that stores the operation history of the industrial machine, and also functions as a maintenance history storage unit that stores the history of maintenance work on the industrial machine. Furthermore, the evaluation device 30 includes an evaluation unit 33b that evaluates the condition of the industrial machine based on the operation history and the maintenance work history, and the evaluation unit 33b outputs, as a result of the evaluation, the use of the industrial machine after it is recovered. Therefore, the condition of the industrial machinery can be evaluated with high accuracy taking into account its operation history and maintenance history, and post-retirement uses can be suggested.

[0044] In addition, the evaluation unit 33b selects a use for the recovered industrial machinery from among uses including at least one of the following: first reuse, in which the industrial machinery is reused after being changed to a configuration that exhibits higher performance than the initial state; second reuse, in which the industrial machinery is reused after being restored to a state close to the initial state; third reuse, in which the industrial machinery is reused after being maintained in an operable state; and part recovery, in which the industrial machinery is reused on a part-by-part basis. This allows for the presentation of specific applications suited to the state of industrial machinery.

[0045] In addition, the evaluation unit 33b evaluates that the first reuse can be offered for either sale or subscription, evaluates that the second reuse can be offered for subscription, and evaluates that the third reuse can be offered for sale. Therefore, it is possible to present the method of providing the industrial machine along with its use.

[0046] The evaluation unit 33b also evaluates the state of the industrial machine by using any one of the history of abnormalities that have occurred in the industrial machine, information on the operating environment of the industrial machine, and the amount of the same model in circulation. This allows for more appropriate selection of uses for the recovered industrial machinery.

[0047] Furthermore, the evaluation unit 33b further outputs the assessed value of the industrial machine as a result of the evaluation, thereby making it possible to present the value of the industrial machine in monetary terms.

[0048] The present invention is not limited to the above-described embodiments, but includes various modifications. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those including all of the described configurations. Furthermore, not only can the configurations be deleted, but also replacements and additions of configurations are possible. For example, although a compressor is exemplified in the above embodiment, the present invention may be applied to a pump, a printer, or other fluid machinery. Furthermore, each data item can be changed as needed, and how the data is used to evaluate the operation and maintenance status can also be changed as needed. [Explanation of symbols]

[0049] 10: Compressor 20: Server 21, 31: Communications Department 22, 32: CPU 23, 33: Main memory 23a: Equipment management department 23b: Data collection section 24, 34: Auxiliary storage device 24a: Equipment management data 24b: Operation history data 24c: Maintenance history data 24d: Abnormality history data 24e: Environmental Information Data 30: Evaluation device 31: Communications Department 33a: Data acquisition section 33b: Evaluation section 33c: Output processing section 41~43: Management terminal

Claims

1. an operation history storage unit that stores the operation history of the industrial machine; a maintenance history storage unit that stores a history of maintenance work on the industrial machine; an evaluation unit that evaluates a state of the industrial machine based on the operation history and the maintenance work history, The machine evaluation system is characterized in that the evaluation unit outputs, as a result of the evaluation, the use of the industrial machine after it is recovered.

2. 2. The machine evaluation system of claim 1, The machine evaluation system is characterized in that the evaluation unit selects a use for the recovered industrial machine from uses including at least one of the following: first reuse, in which the machine is reconfigured to have higher performance than its initial state and used again; second reuse, in which the machine is returned to a state close to its initial state and used again; third reuse, in which the machine is reconditioned to an operable state and used again; and part recovery, in which the machine is used in parts.

3. 3. The machine evaluation system according to claim 2, A machine evaluation system characterized in that the evaluation unit evaluates the first reuse as being possible for either sale or provision by subscription, evaluates the second reuse as being possible for provision by subscription, and evaluates the third reuse as being possible for sale.

4. 2. The machine evaluation system of claim 1, A machine evaluation system characterized in that the evaluation unit evaluates the condition of the industrial machine by further using any of the history of abnormalities that have occurred in the industrial machine, information on the operating environment of the industrial machine, and the amount of the same model in circulation.

5. 2. The machine evaluation system of claim 1, The machine evaluation system is characterized in that the evaluation unit further outputs an appraised value of the industrial machine as a result of the evaluation.

6. 2. The machine evaluation system of claim 1, The machine evaluation system is characterized in that the industrial machine is one of a compressor, a pump, and a printing machine.

7. The computer acquiring an operation history of the industrial machine to be evaluated; acquiring a history of maintenance work on the industrial machine; evaluating a state of the industrial machine based on the operation history and the maintenance work history; a step of outputting, as a result of the evaluation, a use of the industrial machine after it is collected; A machine evaluation method comprising:

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