Industrial machine management system and industrial machine management method

Abstract

To appropriately execute management and collection of a state of an industrial machine.SOLUTION: An industrial machine management system that manages identification information of an industrial machine and operation-related information related to an operation of the industrial machine in association with each other includes a wear degree estimating unit that estimates a wear degree indicating a degree of deterioration due to use for each component included in the industrial machine based on the identification information of the industrial machine and the operation-related information, a state evaluating unit that evaluates a state of the industrial machine based on a wear degree of one or more components included in the industrial machine, a storage unit that stores a device evaluation that is an evaluation result of the state of the industrial machine and the wear degree of one or more components included in the industrial machine for each industrial machine, and a maintenance plan formulating unit that formulates a maintenance plan for the industrial machine based on the wear degree and the device evaluation.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an industrial machinery management system and an industrial machinery management method. [Background technology]

[0002] A unidirectional economic system in which products are provided, consumed, and then discarded is called a linear economy. An economic system in which products and raw materials that would otherwise be discarded in a linear economy are treated as new resources and circulated is called a circular economy (circular market economy). In order to recycle products and materials as part of a circular economy, it is important for end users to recover products that have been in use. Patent Document 1 states, "We provide a leased object recovery system that enables smooth recovery of leased objects and effortless recycling, thereby enabling users to achieve zero emissions and reducing the burden on manufacturers." "A management company 5 that purchases leased objects 9 from manufacturers 1 and leases them to users 6 is provided with a leased object recovery system (company 7) that is primarily comprised of a server device and the like, and that has a calculation unit 8 that calculates the lease fee when leasing the leased objects 5 to users 6. When collecting the leased objects 9 from users 6 after the lease period has expired, the calculation unit 8 calculates the lease fee by adding in advance the disposal costs required for disposing of or recycling the leased objects 9 to the lease fee." [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2007-257430 Summary of the Invention [Problem to be solved by the invention]

[0004] In order to recover products and make them usable again, it is important to properly manage the product condition and recover them at the appropriate time. For example, even if a part can be repaired and reused if recovered early, if recovery is delayed it may become completely damaged and have to be discarded. Furthermore, delayed recovery may result in increased repair costs, undermining the benefits of reuse. Therefore, an object of the present invention is to appropriately manage the state of industrial machinery and perform recovery. [Means for solving the problem]

[0005] In order to achieve the above-mentioned object, one representative industrial machinery management system of the present invention is an industrial machinery management system that manages identification information of industrial machinery in association with operation-related information related to the operation of the industrial machinery, and is characterized by comprising: a wear estimation unit that estimates a wear level indicating the degree of deterioration due to use for each part included in the industrial machinery based on the identification information of the industrial machinery and the operation-related information; a condition evaluation unit that evaluates the condition of the industrial machinery based on the wear levels of one or more parts included in the industrial machinery; a memory unit that stores, for each industrial machine, an equipment evaluation that is the evaluation result of the condition of the industrial machine and the wear levels of one or more parts included in the industrial machine; and a maintenance plan formulation unit that formulates a maintenance plan for the industrial machinery based on the wear levels and the equipment evaluation. Furthermore, one representative industrial machinery management method of the present invention is characterized in that it includes the following steps: a wear estimation step in which a server that manages identification information of industrial machinery and operation-related information related to the operation of the industrial machinery in association with each other estimates a wear degree indicating the degree of deterioration due to use for each part included in the industrial machinery based on the identification information of the industrial machinery and the operation-related information; a condition evaluation step in which the condition of the industrial machinery is evaluated based on the wear degrees of one or more parts included in the industrial machinery; a step in which, for each industrial machinery, an equipment evaluation that is the evaluation result of the condition of the industrial machinery is associated with the wear degrees of one or more parts included in the industrial machinery and stored in a storage device; and a maintenance plan formulation step in which a maintenance plan for the industrial machinery is formulated based on the wear degrees and the equipment evaluation. [Effects of the Invention]

[0006] According to the present invention, it is possible to appropriately manage and recover the state of industrial machinery. 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] Diagram of industrial machinery management [Figure 2] Modified industrial machinery management [Figure 3] Pump configuration diagram [Figure 4] Industrial Machinery Management System [Figure 5] An example of system configuration [Figure 6] Server configuration diagram [Figure 7] Specific examples of various data (part 1) [Figure 8] Specific examples of various data (part 2) [Figure 9] Example of the management screen (part 1) [Figure 10] Example of the admin screen (part 2) [Figure 11] State estimation evaluator configuration diagram [Figure 12]Flowchart showing the processing procedure of the state estimation evaluator [Figure 13] Diagram of the remanufactured product cycle [Figure 14] Illustrative diagram of quality classification at remanufacturing level 0 [Figure 15] 1 is a flow chart illustrating the operation of the pump supply system. [Figure 16] Flowchart showing details of inquiry order processing [Figure 17] Illustration of part wear estimation [Figure 18] Example of life expectancy estimation for inverter power switching elements [Figure 19] Example of inverter smoothing capacitor life expectancy estimation [Figure 20] Flowchart showing the maintenance plan formulation process [Figure 21] Flowchart showing pump collection and replacement procedures [Figure 22] Flowchart showing on-site maintenance procedures [Figure 23] Flowchart showing the procedure for pre-remanufacturing evaluation [Figure 24] Flowchart showing the remanufacturing process [Figure 25] Flowchart showing the post-remanufacturing evaluation process [Figure 26] Example of a configuration where a manufacturer lends equipment to an end user DETAILED DESCRIPTION OF THE INVENTION

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

[0009] Figure 1 is an explanatory diagram of industrial machinery management. In Figure 1, a manufacturer produces pumps, which are industrial machines. Pump manufacturing can be either new production using all new parts or remanufacturing using at least some recovered pumps. Specifically, remanufacturing is carried out by repairing and servicing the recovered pump itself, replacing parts, or repairing and servicing recovered pump parts before using them. Remanufactured pumps have performance equal to or better than newly manufactured pumps, and have quality sufficiently close to that of newly manufactured pumps.

[0010] A manufacturer sells pumps to a leasing company under a buy-back contract with a call option. In Figure 1, the manufacturer's remanufacturing facility L3 sells remanufactured pumps to leasing company L5. In addition, the manufacturer's remanufacturing facility L3 purchases recovered pumps from leasing company L5.

[0011] Leasing company L5 enters into a subscription contract with end user L1. This subscription contract provides a specified water pumping capacity for the contract period. In other words, end user L1 does not purchase the pump itself, but instead pays for the pump's water pumping capacity. In addition, leasing company L5 has entered into a service outsourcing contract for maintenance work with manufacturer service center L2.

[0012] Leasing company L5 manages the equipment (pumps) purchased from manufacturers and leased to users. Leasing company L5 also manages contracts with manufacturer remanufacturing base L3, end users L1, and manufacturer service base L2.

[0013] Leasing company L5 collects subscription fees from end users L1, pays a fixed monthly service fee to manufacturer service center L2, and keeps the remainder as funds or profits.

[0014] The manufacturer service base L2 receives delivery of the pump from the manufacturer remanufacturing base L3 and delivers the pump directly to the end user L1. The manufacturer service base L2 remotely monitors the operating status of the pump at the end user L1 and acquires monitoring data. The manufacturer service base L2 estimates the status of the pump based on the monitoring data and evaluates whether maintenance work is necessary. The manufacturer service base L2 provides maintenance service as necessary. When collecting the pump, the manufacturer service base L2 collects the pump directly from the end user L1. The pump collected by the manufacturer service base L2 from the end user L1 is collected by the manufacturer remanufacturing base L3.

[0015] The manufacturer's remanufacturing base L3 evaluates and remanufactures the pumps (recovered products) collected via the manufacturer's service base L2. The manufacturer then guarantees the quality of the remanufactured pumps and uses them for the next delivery. In this way, the manufacturer's remanufacturing base L3 comprehensively manages the cycle of remanufacturing, delivery, collection, and further remanufacturing of pumps.

[0016] The manufacturer server L4 stores various data used by the manufacturer service base L2 and the manufacturer remanufacturing base L3. For example, the manufacturer server L4 stores a quality control database, a customer management database, an operation management database, an estimation model database, and the like.

[0017] FIG. 2 shows a modified example of industrial machinery management. In FIG. 2, a state estimation / evaluation server L6 remotely monitors the operating state of a pump at an end user L1 and acquires monitoring data. The state estimation / evaluation server L6 estimates the state of the pump based on the monitoring data, evaluates whether maintenance work is necessary, and outputs the result to a manufacturer service center L2. The manufacturer service center L2 uses the evaluation results of the state estimation / evaluation server L6 to provide maintenance service as necessary. The other configurations and operations are the same as those in FIG. 1, so explanations will be omitted.

[0018] Figure 3 is an explanatory diagram of the configuration of the pump. The remanufactured pump device 10 shown in Figure 3 has a pump unit 11, an electric motor 12, a control device 13, a sensor unit 14, and a communication device 15. The pump unit 11 is a main body that is powered by the electric motor 12 to pump water. The control device 13 controls the water pumping by the pump unit 11. The sensor unit 14 acquires the overall status of the remanufactured pump device. The communication device 15 transmits data indicating the overall status of the remanufactured pump device acquired by the sensor unit 14 as monitoring data to the manufacturer service center L2 or the status estimation evaluation server L6. The sensor unit 14 may be included in the control device 13.

[0019] The pump unit 11, the electric motor 12, the control device 13, the sensor unit 14, and the communication device 15 are replaceable units. Each of the pump unit 11, the electric motor 12, the control device 13, the sensor unit 14, and the communication device 15 includes one or more parts. Based on the monitoring data, the industrial machinery management system estimates the degree of wear for each part, which indicates the degree of deterioration due to use. Then, the state of the remanufactured pump device 10 and the state of each unit are evaluated based on the degree of wear for the parts.

[0020] Fig. 4 is an explanatory diagram of an industrial machinery management system. Fig. 4 shows a server 20 and a state estimation evaluator 30, with a remanufactured pump device 10 as the management target. The server 20 and the state estimation evaluator 30 may be located at a manufacturer service base L2. Alternatively, a state estimation evaluation server L6 may have the functions of the server 20 and the state estimation evaluator 30. Alternatively, the server 20 and the state estimation evaluator 30 may have some or all of the functions of the manufacturer service base L2 and the manufacturer remanufacturing base L3.

[0021] The server 20 monitors the status of multiple remanufactured pump devices 10. Specifically, the server 20 manages pump management data 24a, operation history data 24b, maintenance history data 24c, abnormality history data 24d, environmental information data 24e, remanufacturing history data 24f, and each part state estimation data 24g, etc., for the multiple remanufactured pump devices 10.

[0022] The pump management data 24a is data for managing a pump ID that identifies the remanufactured pump device 10 in association with an installation location, a user, and the like. The operation history data 24b is data in which operation information acquired from the remanufactured pump device 10 is stored in association with the pump ID. The maintenance history data 24c is data in which maintenance work performed on the remanufactured pump device 10 is associated with the pump ID and stored. The abnormality history data 24d is data in which abnormalities that have occurred in the remanufactured pump device 10 are associated with the pump ID and stored. The environmental information data 24e is data that is accumulated by associating the operating environment of the remanufactured pump device 10 with the pump ID. The remanufacturing history data 24f is data showing the remanufacturing history of the remanufactured pump device 10 based on the pump ID. The component state estimation data 24g is data indicating the state of components included in the remanufactured pump device 10 in association with the pump ID. The data managed by the server 20 is not limited to the above, and for example, if necessary for estimating the state of the remanufacturing pump device 10, the state of related equipment may also be added as needed.

[0023] The state estimation evaluator 30 uses various data from the server 20 to estimate the state of each part and detect signs of abnormality in each part. The state estimation evaluator 30 comprehensively judges and evaluates the state of the remanufactured pump device 10 based on the results of estimating the state of each part and the results of detecting signs of abnormality in each part. Then, based on the judgment results, it outputs maintenance instructions and judges the level of remanufacturing. The level of remanufacturing indicates how much man-hours are required to make the product ready for shipment as a remanufactured product. Remanufacturing levels include "low-cost remanufacturing," "medium-cost remanufacturing," "high-cost remanufacturing," and "disposal recycling."

[0024] "Low-cost remanufacturing" is a level at which products can be remanufactured with a small number of steps, such as being recovered relatively soon after delivery. "Medium-cost remanufacturing" is a level at which the product can be remanufactured with a medium amount of labor. "High cost remanufacturing" is a level where a large number of man-hours are required to produce a remanufactured product. "Disposal recycling" is the level at which products are disposed of without being remanufactured, or recycled on a component-by-component basis.

[0025] FIG. 5 shows an example of a system configuration. Remanufactured pump equipment 10 is delivered to and used at each of multiple customer sites L1-1, L1-2, etc. The multiple remanufactured pump equipment 10 is connected to a server 20 via a network and transmits information such as operating status to the server 20. A management terminal 41 is also installed at each of the manufacturer's service center L2, manufacturer's remanufacturing center L3, and leasing company L5. The management terminal 41 is connected to the server 20 via the network. A state estimation evaluator 30 is also connected to the server 20.

[0026] FIG. 6 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.

[0027] The communication unit 21 is an interface for communicating with the remanufactured pump device 10 and the management terminal 41. 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.

[0028] 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 pump management data 24a, operation history data 24b, maintenance history data 24c, abnormality history data 24d, environmental information data 24e, remanufacturing history data 24f, and part state estimation data 24g.

[0029] The device management unit 23a manages, as pump management data 24a, information such as where each remanufactured pump device 10 is installed. The data collection unit 23b acquires data on the operation, maintenance, abnormalities, operating environment, remanufacturing history, and estimated state of the remanufactured pump device 10 at any time, and manages the data by accumulating it in operation history data 24b, maintenance history data 24c, abnormality history data 24d, environmental information data 24e, remanufacturing history data 24f, and estimated state data for each part 24g.

[0030] 7 and 8 show specific examples of various data. The pump management data 24a shown in Figure 7 associates the pump ID with data on model, serial number, installation location, purpose, liquid quality, serial number, remanufacturing, and contract renewal. Figure 7 shows an example of pump ID "ID0001," model "AX...," installation location "B Factory...," purpose "Air Conditioning Refrigeration...," liquid quality "pH 7-8," serial number "CY...," remanufacturing "2021 / 08," and contract renewal "2027 / 10."

[0031] The operation history data 24b shown in Fig. 7 associates the pump ID with the acquisition date and time, operating state, maximum current, number of startups, cumulative operating time, and cumulative startup count. Fig. 7 shows an example of pump ID "ID0001," acquisition date and time "2024 / 04 / 30," operating state "normal," maximum current "27.4A," number of startups "2.6 times / day," cumulative operating time "17,568h," and cumulative startup count "2,379 times."

[0032] The maintenance history data 24c shown in Figure 7 associates the pump ID with the date and time of the maintenance, the maintenance task, the maintenance result, and the maintenance technician. Figure 7 shows an example of the pump ID "ID0001," the date and time "2024 / 03 / 24 16:25:43," the maintenance task "mechanical seal inspection and adjustment," the maintenance result "no abnormalities," and the maintenance technician "xx xx." Furthermore, the maintenance information is not limited to this example, and any other information can be included.

[0033] The abnormality history data 24d shown in Figure 7 associates the pump ID with the date and time of occurrence, the abnormality content, the countermeasure result, and the person in charge of the countermeasure. Figure 7 shows an example of pump ID "ID0001," date and time "2024 / 02 / 18 22:34:56," the abnormality content "undervoltage trip," the countermeasure result "restored, manual release," and maintenance person "yy yy." Furthermore, any information related to alarms and failures can be included, not limited to the example.

[0034] The environmental information data 24e shown in Figure 8 associates the pump ID with the acquisition date and time, latest ambient temperature, monthly average ambient temperature, and average ambient temperature. Figure 8 shows an example of pump ID "ID0001," acquisition date and time "2024 / 04 / 30 12:33:45," latest ambient temperature "28°C," monthly average ambient temperature "19°C," and average ambient temperature "27°C." This example is not limiting, and any information related to the operating environment of the remanufactured pump device 10 can be included.

[0035] The remanufacturing history data 24f shown in FIG. 8 associates a pump ID with a remanufacturing date, a remanufacturing history, a level, and special notes. FIG. 8 shows an example of a pump ID "ID0001," a remanufacturing date "2009 / 03 / 24," a remanufacturing history "new," a level "-," and a special note "new." FIG. 8 also shows an example of a pump ID "ID0001," a remanufacturing date "2015 / 06 / 25," a remanufacturing history "first remanufacturing," a level "1," and a special note "none." FIG. 8 also shows an example of a pump ID "ID0001," a remanufacturing date "2021 / 08 / 25," a remanufacturing history "second remanufacturing," a level "2," and a special note "present."

[0036] The component condition estimation data 24g shown in Figure 8 associates the pump ID with the condition estimation date, the wear level of the pump component, the wear level of the motor component, the wear level of the inverter component, the wear level of the communication equipment, the wear level of the sensor component, and an overall judgment. Figure 8 shows an example of pump ID "ID0001," condition estimation date "2024 / 04 / 30," the wear level of the pump component "62%," the wear level of the motor component "32%," the wear level of the inverter component "28%," the wear level of the communication equipment "5%," the wear level of the sensor component "18%, and an overall judgment "B." The wear level indicates the degree of deterioration due to use, with the wear level of a new product being 0% and the wear level of a state that is no longer usable being 100%. The overall judgment indicates the result of judging the condition of the remanufactured pump device 10 based on the wear level of each component. The part state estimation data 24g includes the degree of wear not only for each unit but also for each part, and the degree of wear of each unit is calculated from the degree of wear of the parts included in that unit.

[0037] 9 and 10 are examples of the management screen. The management terminal 41 at the manufacturer service base L2 generates a management screen using data acquired from the server 20 and displays it on the display.

[0038] 9 shows data for pump ID "ID0001" extracted from the pump management data 24a, operation history data 24b, maintenance history data 24c, abnormality history data 24d, and environmental information data 24e. It also shows data on the next scheduled maintenance for pump ID "ID0001."

[0039] In Figure 10, data for pump ID "ID0001" is extracted and displayed from pump management data 24a, remanufacturing history data 24f, and part status estimation data 24g. Here, the part status estimation data 24g displays both the wear level for each unit and each part. Furthermore, the estimated remaining life obtained from the wear level is displayed, along with whether maintenance is required and the deadline for maintenance.

[0040] FIG. 11 is a configuration diagram of the state estimation evaluator 30. The state estimation evaluator 30 is a computer having a communication unit 31, a generation AI 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.

[0041] The communication unit 31 is an interface for communicating with the server 20 . The generation AI 32 is executed by a predetermined processor and performs processing using a large amount of data. The predetermined processor also reads predetermined programs from the auxiliary storage device 34 or the like, loads them into the main storage device 33, and executes them sequentially to realize various functions. The realized functions include a data acquisition unit 33a, a wear degree estimation unit 33b, an abnormality sign detection unit 33c, a remaining life estimation unit 33d, a maintenance plan formulation unit 33e, and an output processing unit 33f. The auxiliary storage device 34 stores a wear estimation model 34a, an abnormality sign detection model 34b, a life prediction model 34c, and the like.

[0042] The data acquisition unit 33 a is a processing unit that acquires various data from the server 20 . The wear degree estimation unit 33b estimates the wear degree, which indicates the degree of deterioration due to use, for each part included in the remanufactured pump device 10, based on the operation-related information associated with the pump ID. The operation-related information includes information acquired by the sensor unit 14. In addition, the pump management data 24a, the operation history data 24b, the maintenance history data 24c, the abnormality history data 24d, and the environmental information data 24e may also be used.

[0043] The wear degree estimation unit 33b estimates the wear degree of at least one part by using a wear degree estimation model 34a, which is a learning model. Furthermore, when the wear level fluctuates at a rate equal to or greater than a predetermined rate, the wear level estimating unit 33b outputs possible causes of the fluctuation from the driving-related information before and after the fluctuation.

[0044] The abnormality sign detection unit 33c detects abnormality signs from operation-related information. For example, if there are fluctuations in the ambient temperature, maximum current, number of startups, or operating time, it can be estimated that an abnormality may occur earlier than it actually does. While these data can be used individually as abnormality signs, combining multiple data and detecting signs using the abnormality sign detection model 34b makes it possible to predict in advance the occurrence of an abnormality caused by a combination of multiple factors.

[0045] The remaining life estimation unit 33d is a condition evaluation unit that evaluates the condition of the remanufactured pump equipment 10 based on the degree of wear of one or more parts included in the equipment. For convenience, this evaluation result is referred to as equipment evaluation. One of the equipment evaluations is the remaining time until the equipment is collected, estimated from the degree of wear, i.e., the remaining life. A life prediction model 34c, which is a learning model, is used to calculate the remaining life. Furthermore, the remaining life estimation unit 33d evaluates the state of each unit of the remanufactured pump device 10 based on the degree of wear of the parts included in the unit.

[0046] The remaining life estimation unit 33d determines a remanufacturing level for the collected remanufactured pump device 10, which indicates the burden required for remanufacturing. When parts of the recovered remanufactured pump device 10 are replaced, the remaining life estimation unit 33d reevaluates the condition of the device based on the degree of wear of the parts installed as a result of the replacement, and provides the device to the user again based on the results of the reevaluation, repairing the parts removed as a result of the replacement and making them available for replacement from the next time onwards. Furthermore, the remaining life estimation unit 33d receives information on the results of maintenance work performed on the remanufactured pump apparatus 10 and updates the wear level of the parts. The remaining life estimation unit 33d updates the evaluation of the remanufactured pump apparatus 10 based on the updated wear level. At this time, in addition to updating the remaining life, it also determines the grade that serves as a criterion for determining the use and rental period. Furthermore, the remaining life estimation unit 33d obtains the results of a direct evaluation of the wear degree of the parts of the remanufactured pump device 10 recovered based on the maintenance plan, and uses the difference between the wear degree evaluated on the direct evaluation of the parts and the wear degree estimated by the learning model as training data for updating the learning model.

[0047] The maintenance plan formulation unit 33e formulates a maintenance plan for the remanufactured pump apparatus 10 based on the degree of wear of the parts and an evaluation (equipment evaluation) of the remanufactured pump apparatus 10. The maintenance plan formulation unit 33e determines the timing of performing maintenance work based on the degree of wear, the equipment evaluation, and the remaining rental period.

[0048] Specifically, the maintenance plan formulation unit 33e calculates a maintenance plan that indicates information about parts that require maintenance work and the time allowance until the maintenance work is performed when the wear level of at least one of the parts that make up the remanufactured pump device 10 reaches a predetermined value.

[0049] Furthermore, the maintenance plan formulation unit 33e determines whether or not the remanufactured pump apparatus 10 itself needs to be recalled for maintenance work based on the parts that require maintenance work. If the remanufactured pump apparatus 10 itself does not need to be recalled, a plan is formulated to perform maintenance work on other parts so that the period until the next maintenance work is at least a predetermined time after the maintenance work is performed. If the remanufactured pump apparatus 10 itself needs to be recalled, a date for the recall of the remanufactured pump apparatus 10 itself is determined, and a plan is formulated to perform on-site maintenance work on the parts that require maintenance work by that date.

[0050] When the remanufactured pumping device 10 itself is collected, a replacement remanufactured pumping device 10 is delivered and the remanufactured pumping device 10 is replaced. This is because a specific remanufactured pumping device 10 is not sold to the user, but rather a contract is made to provide a specified water delivery capacity using the remanufactured pumping device 10. When replacing a remanufactured pump device 10 to be provided to a user, the maintenance plan formulation unit 33e determines, based on the user's operating environment and the remaining rental period, what equipment evaluation of the remanufactured pump device 10 is appropriate for the new remanufactured pump device 10 to be provided as a replacement.

[0051] The maintenance plan formulation unit 33e determines the content of maintenance work based on the results of detecting signs of abnormalities and the lifespan of parts determined by the degree of wear. Furthermore, the maintenance plan formulation unit 33e outputs information about carbon dioxide emissions according to the results of executing the maintenance plan.

[0052] The output processing unit 33f is a processing unit that outputs various data generated by the state estimation evaluator 30. The output processing unit 33f transmits, for example, the degree of wear of parts, the evaluation of the unit, the equipment evaluation of the remanufactured pump device 10, the maintenance plan, the amount of carbon dioxide emissions, etc., as a response to a request from the management terminal 41. It is also possible to output the data to a display device connected to the server 20 or the state estimation evaluator 30.

[0053] 12 is a flowchart showing the processing procedure of the state estimation evaluator 30. The state estimation evaluator 30 sequentially executes the following steps S101 to S110. In step S101, the data acquisition unit 33a identifies the pump ID of the target device. Then, the process proceeds to step S102. The target device is the remanufactured pump device 10 currently being used by the user.

[0054] In step S102, the data acquisition unit 33a searches the operation history data 24b of the server 20 using the pump ID to acquire the operation history of the target device. Step S103: The data acquisition unit 33a searches the maintenance history data 24c of the server 20 using the pump 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 pump 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 environmental information data 24e of the server 20 using the pump ID to acquire the history of the operating environment of the target device. Then, the process proceeds to step S106. In step S106, the data acquisition unit 33a searches the part state estimation data 24g of the server 20 using the pump ID, and acquires information indicating the state of each part of the target device. Then, the process proceeds to step S107.

[0055] In step S107, the wear degree estimation unit 33b provides the data acquired by the data acquisition unit 33a to the wear degree estimation model 34a, and estimates the wear degree of each part. This wear degree estimation is an estimation of how much use there is and how much wear has occurred. Then, the process proceeds to step S108. In step S108, the abnormality sign detection unit 33c provides the data acquired by the data acquisition unit 33a to the abnormality sign detection model 34b to detect an abnormality sign, and then the process proceeds to step S109. In step S109, the remaining life estimation unit 33d provides the wear level and abnormality detection results of each part to the life prediction model 34c to estimate the remaining life and state of the target device, and then the process proceeds to step S110. In step S110, the maintenance plan formulation unit 33e formulates and outputs a maintenance plan based on the wear level of each part, the abnormality detection results, and the remaining life and state of the target device, and then ends the process.

[0056] Next, an example of estimating the degree of wear will be described. First, the wear level of the remanufactured pump device 10 is set to f(P, M, I, C, S). Here, P, M, I, C, and S are as follows: P = wear level of pump section = Wear immediately after the previous remanufacturing - Total wear of pump components Pump components = (seals, bearings, impellers, mouths, casings, etc.) M = Motor wear = Wear and tear immediately after the previous remanufacturing - Total wear and tear of motor components Electric motor components = (bearings, stators, rotors, exteriors, etc.) I = Inverter wear level = Wear and tear immediately after the previous remanufacturing - Total wear and tear of inverter components Inverter components (electrolytic capacitors, power elements, control boards, etc.) C = Wear level of communication board S = Sensor wear level

[0057] The degree of wear of each part is estimated and evaluated individually using generative AI, etc., depending on the characteristics of the part in question, such as operating time, number of starts, and temperature. The degree of wear of each part is managed individually and reflected in the maintenance plan output by the condition estimation evaluator.

[0058] Figure 13 is an explanatory diagram of the circulation of remanufactured products. Pumps delivered to users are either remanufactured products with reliability above a standard level or new replenishment products. Since new replenishment products are more expensive to manufacture than remanufactured products, if remanufactured products with reliability above the standard level are available, the remanufactured products are delivered first.

[0059] Once a pump is used by a user at the delivery destination, its reliability and value will decrease. The state of a pump whose reliability and value have decreased will be evaluated as a remanufacturing level 1 to 4. A remanufactured product whose reliability at the time of delivery is at or above the standard level will be rated as remanufacturing level 0, and as it is used, it will progress to remanufacturing level 1, remanufacturing level 2, remanufacturing level 3, and remanufacturing level 4.

[0060] At remanufacturing level 1, the amount of decline in reliability and value is small if the usage time is short, the installation environment is good, and the operating time is short, etc. Therefore, if an item is collected and remanufactured at remanufacturing level 1, the labor required to return it to remanufacturing level 0 is small, and the cost is low.

[0061] Remanufacturing level 2 has a longer usage time and a greater decline in reliability and value than remanufacturing level 1. If a product is collected and remanufactured at remanufacturing level 2, the labor and cost required to return it to remanufacturing level 0 will be medium.

[0062] Remanufacturing level 3 products have a longer usage time and a greater decline in reliability and value than remanufacturing level 2 products. If a product is collected and remanufactured at remanufacturing level 3, the labor required to return it to remanufacturing level 0 will be greater, and the cost will be higher.

[0063] At remanufacturing level 4, the usage time is longer and the amount of deterioration in reliability and value is greater than at remanufacturing level 3. At remanufacturing level 4, even if the equipment is collected, it cannot be remanufactured, and the equipment must be destroyed or recycled on a component-by-component basis.

[0064] In order to make a profit from the remanufacturing business, it is effective to "manage so that value is not lost as much as possible during leasing," recover the goods while the remanufacturing level is still low, and maintain a cycle by minimizing the loop (the loop of value loss due to use and value recovery through remanufacturing) to return the goods to a remanufacturing level of 0.

[0065] FIG. 14 is an explanatory diagram of quality classification at remanufacturing level 0. All remanufactured products at remanufacturing level 0 exceed the standard level of reliability. However, there are differences in quality even within remanufacturing level 0. The condition estimation evaluator 30 evaluates these differences by classifying them as grades. In FIG. 14, the grades of remanufactured products are classified into A to C.

[0066] Grade A is given to discontinued products with a maintenance level of 80 to 99, where the maintenance level of a new replacement part is 100. This corresponds to cases where heavy maintenance has been carried out, with the product being completely disassembled and many parts replaced with new ones. Grade B is given to discontinued products with a maintenance level of 60 to 79. This corresponds to cases where medium maintenance has been performed, where partial disassembly is performed on each part. Grade C is given to discontinued products with a maintenance level of 40 to 59. This corresponds to cases where only key parts have been disassembled and maintained (such as cleaning bearings and refilling grease), replaced, or lightly maintained, such as an overall cleaning.

[0067] This grade is used as a reference when delivering to the next user. In other words, if there is a possibility that the product will be used in a harsh environment, a higher grade remanufactured product will be provided. If the environment is expected to be benign or if early recovery is expected, a lower grade remanufactured product will be provided.

[0068] 15 is a flowchart illustrating the operation of the pump supply system to which the present invention is applied. The pump supply system executes the processes of steps S201 to S205 and steps S211 to S215. In step S201, the manufacturer's remanufacturing base L3 executes inquiry order processing based on inquiry information from the manufacturer's sales department (not shown) or a service representative who has contact with the end user. Then, the process proceeds to step S202. This inquiry is for new installation of a remanufactured pump device 10 or for exchange and collection. In step S202, the manufacturer service base L2 installs the remanufactured pump device 10 at the factory or the like of the end user L1, and exchanges and collects the pump device 10. Then, the process proceeds to step S203. For used product collection, the process proceeds to step S211.

[0069] In step S203, the state estimation evaluator 30 remotely monitors the remanufactured pump device 10 at the end user L1 and estimates the state, and then the process proceeds to step S204. In step S204, the state estimation evaluator 30 determines whether or not maintenance is required for the remanufacturing pump device 10. If maintenance is not required, the process returns to step S203. If maintenance is required, the process proceeds to step S205.

[0070] In step S205, the state estimation evaluator 30 determines whether or not it is necessary to replace or collect the remanufactured pump device 10. If it is not necessary to replace or collect, the process proceeds to step S206. If it is necessary to replace or collect, the process returns to step S201. In step S206, the manufacturer service base L2 carries out maintenance on-site, that is, at the factory of the end user L1, etc. Then, the process returns to step S203.

[0071] In step S211, the manufacturer's remanufacturing base L3 collects the used product, and then the process proceeds to step S212. In step S212, the manufacturer's remanufacturing base L3 evaluates the collected remanufactured pump device 10 before remanufacturing it. Based on this evaluation, the remanufacturing process and maintenance details are determined. Then, the process proceeds to step S213. In step S213, the manufacturer's remanufacturing base L3 carries out remanufacturing using the collected remanufactured pump device 10. Thereafter, the process proceeds to step S214. In step S214, the manufacturer's remanufacturing base L3 evaluates the remanufactured pump device 10. This evaluation determines, for example, the grade and determines the level of quality that can be guaranteed when the pump device 10 is provided to the user again. Then, the process proceeds to step S215. In step S215, the manufacturer's remanufacturing base L3 adds the remanufactured pump device 10 to its inventory, and the process ends.

[0072] 16 is a flowchart showing details of inquiry receiving processing. The manufacturer remanufacturing base L3 (specifically, the management terminal 41 of the manufacturer remanufacturing base L3) determines whether the received inquiry is new or renewal. If it is new, proceed to step S302. If it is renewal, proceed to step S305.

[0073] In step S302, the manufacturer's remanufacturing base L3 acquires the customer information, and the process proceeds to step S303. In step S303, the manufacturer's remanufacturing base L3 acquires the environmental information, and the process proceeds to step S304. In step S304, the manufacturer's remanufacturing base L3 sets the customer's environmental conditions, and the process proceeds to step S307.

[0074] Step S305: The manufacturer's remanufacturing base L3 checks the customer registration information, and then the process proceeds to step S306. In step S306, the manufacturer's remanufacturing base L3 checks the operation management information, and then the process proceeds to step S307. In step S307, the manufacturer's remanufacturing base L3 updates the customer's environmental conditions, and the process proceeds to step S308.

[0075] In step S308, the manufacturer's remanufacturing base L3 refers to the grade of the remanufactured product inventory and the customer's environmental conditions, and determines whether the remanufactured product inventory meets the customer's conditions, and then proceeds to step S309. In step S309, the manufacturer remanufacturing base L3 determines whether or not stock allocation is possible depending on whether the remanufactured product stock meets the customer's requirements. If it is determined that stock allocation is possible, the process proceeds to step S310. If it is determined that stock allocation is not possible, the process proceeds to step S311.

[0076] In step S310, the manufacturer's remanufacturing base L3 allocates the remanufactured product from its inventory, and the process proceeds to step S312. In step S311, the manufacturer's remanufacturing base L3 allocates a new part, and the process proceeds to step S312. In step S312, the manufacturer's remanufacturing base L3 determines and outputs the delivery date, and the process ends.

[0077] 17 is an explanatory diagram of estimation of the wear degree of a part. The condition estimation evaluator 30 sequentially executes the following steps S401 to S410. In step S401, the data acquisition unit 33a acquires the use conditions and the environmental conditions, and then the process proceeds to step S402. In step S402, the wear level estimation unit 33b estimates the lifespan of each part based on the use conditions and environmental conditions, and then the process proceeds to step S403. In step S403, the wear level estimating unit 33b sets the estimated lifespan of each component as an initial value for determining the lifespan, and then the process proceeds to step S404.

[0078] In step S404, the data acquisition unit 33a acquires and stores the monitoring data, and then the process proceeds to step S405. Step S405: The wear degree estimation unit 33b estimates the wear degree of the part using the wear degree estimation model 34a, and the abnormality sign detection unit 33c detects an abnormality sign using the abnormality sign detection model 34b. Then, the process proceeds to step S406.

[0079] In step S406, the maintenance plan formulation unit 33e determines whether the remaining life of the part determined from the degree of wear is less than the threshold value of the part's life (life NG state) or whether a sign of an abnormality has been detected. If the part is in the life NG state or a sign of an abnormality has been detected, the process proceeds to step S407. If the part is not in the life NG state and a sign of an abnormality has not been detected, the process proceeds to step S408.

[0080] In step S407, the maintenance plan formulation unit 33e creates and outputs a maintenance plan, and then the process proceeds to step S408. In step S408, the wear level estimation unit 33b determines whether or not three months have passed since the start of acquisition of monitoring data. If three months have not passed, the process returns to step S404. If three months have passed, the process proceeds to step S409.

[0081] In step S409, the wear level estimation unit 33b determines whether there is a difference between the set conditions and the monitoring data. If there is a difference, the process proceeds to step S410. If there is no difference, the process proceeds to step S402. In step S410, the wear level estimation unit 33b updates the use conditions and environmental conditions, and then the process proceeds to step S402. In this way, the condition estimation evaluator 30 compares the initial usage environment conditions and operating conditions with the operating and environmental data for the most recent quarter, for example, every quarter, and recalculates and reviews the lifespan judgment value if necessary. This allows the actual operating environment on the user's side to be reflected in the deterioration estimation process for each part, thereby improving the accuracy of the estimation. Furthermore, during an overhaul (such as returning the device to the factory for remanufacturing) every six years, when the device is disassembled, the actual condition of the parts is reflected in the results of the deterioration estimation process, thereby continuously improving the estimation accuracy of the deterioration estimation process.

[0082] 18 shows a specific example of the lifespan estimation of the power switching elements of the inverter. The wear level estimation unit 33b sequentially executes the following steps S501 to S507. In step S501, the wear level estimation unit 33b reads out the previously set use conditions and environmental conditions based on the pump ID, and then proceeds to step S502. In step S502, the wear level estimation unit 33b reads the operation history data and the environmental information data obtained by remote monitoring from the previous time to the current time, and then proceeds to step S503. In step S503, the wear level estimating unit 33b calculates the number of power cycles in this period based on the ambient temperature, the number of starts and stops, the operating time, the current during operation, etc. Then, the process proceeds to step S504.

[0083] In step S504, the wear level estimating unit 33b adds the accumulated number of power cycle lifespans up to the previous time to the accumulated number of power cycle lifespans, updates the accumulated number of power cycle lifespans, and stores the updated number of power cycle lifespans.Then, the process proceeds to step S505. In step S505, the wear level estimating unit 33b subtracts the cumulative power cycle life number calculated this time from the power cycle life number at the time of design to calculate the remaining power cycle life number until the design life, and then proceeds to step S506. In step S506, the wear level estimating unit 33b recalculates and updates the remaining life time based on the operating history and environmental information from the previous time to the current time, and then the process proceeds to step S507. In step S507, the wear level estimating unit 33b updates the previously set customer use environmental conditions to the current customer use environmental conditions and stores them. After that, the process proceeds to an equipment evaluation process in which the remanufactured pump device 10 itself is evaluated. In this way, by continuously managing the cumulative number of power cycle lifespans, it becomes possible to manage the state of component deterioration for each individual inverter based on its current usage environment, even if maintenance, including inverter remanufacturing, is repeated.

[0084] 19 is a specific example of the lifespan estimation of a smoothing capacitor of an inverter. The wear level estimation unit 33b sequentially executes the following steps S601 to S507. In step S601, the wear level estimation unit 33b reads out the previously set use conditions and environmental conditions based on the ID, and then proceeds to step S602. In step S602, the wear level estimation unit 33b reads the operation history and environmental information obtained by remote monitoring from the previous time to the current time, and then proceeds to step S603. In step S603, the wear level estimating unit 33b calculates the time product at the estimated internal temperature during operation in this period, that is, the life consumption rate, using Arrhenius' law, based on the ambient temperature, operation time, current during operation, etc. Then, the process proceeds to step S604.

[0085] In step S604, the wear level estimating unit 33b adds the currently calculated cumulative life consumption rate to the cumulative life consumption rate based on the previous operation, updates the cumulative life consumption rate of the capacitor, and stores the updated cumulative life consumption rate. Then, the process proceeds to step S605. In step S605, the wear level estimating unit 33b subtracts the life time based on the cumulative life consumption rate calculated this time from the estimated life at the time of design (category upper limit value, time) to calculate the remaining estimated life until the element life ends. Then, the process proceeds to step S606. In step S606, the wear level estimating unit 33b calculates and updates the remaining estimated life time based on the operating history from the previous time to the current time and the environmental information, and then proceeds to step S607. In step S607, the wear level estimating unit 33b updates the previously set customer use environmental conditions to the current customer use environmental conditions and stores them. After that, the process proceeds to an equipment evaluation process in which the remanufactured pump device 10 itself is evaluated. In this way, by continuously managing the cumulative life consumption rate, it becomes possible to manage the state of component deterioration for each individual inverter based on its current usage environment, even if maintenance, including inverter remanufacturing, is repeated.

[0086] 20 is a flowchart showing the processing procedure for formulating a maintenance plan. The maintenance plan formulating unit 33e sequentially executes the following steps S701 to S709. In step S701, the maintenance plan formulation unit 33e determines whether or not it is necessary to collect the remanufactured pump apparatus 10 itself in order to perform maintenance on the target part. If it is not necessary, the process proceeds to step S702. If it is necessary, the process proceeds to step S704.

[0087] In step S702, the maintenance plan formulation unit 33e determines whether there are any other parts that will reach the end of their life within six months and that will require the collection of the remanufactured pump device 10 itself for maintenance. If there are any such parts, the process proceeds to step S704. If there are no such parts, the process proceeds to step S703. In step S703, the maintenance plan formulation unit 33e checks other parts that need to be maintained at the same time, and then the process proceeds to step S707.

[0088] In step S704, the maintenance plan formulation unit 33e checks the allocation of a remanufactured product for replacement or the procurement delivery date of a new product, and then proceeds to step S705. In step S705, the maintenance plan formulation unit 33e formulates a recovery and replacement work schedule for the remanufactured pump device 10. After that, the process proceeds to step S706. In step S706, the maintenance plan formulation unit 33e determines whether there are any parts that will reach the end of their lifespan before the due date for the collection and replacement work of the remanufactured pump device 10. If there are any such parts, the process proceeds to step S707. If there are no such parts, the process proceeds to step S709.

[0089] In step S707, the maintenance plan formulation unit 33e checks the allocation and procurement delivery date of the parts to be used for on-site replacement. Then, the process proceeds to step S708. The parts to be used for on-site replacement may be new parts, rebuilt parts that have been previously repaired and are in stock at the manufacturer of the remanufactured pump device 10, or parts remanufactured by the parts manufacturer.

[0090] In step S708, the maintenance plan formulation unit 33e creates a schedule for the on-site maintenance work plan, and then the process proceeds to step S709. In step S709, the maintenance plan formulation unit 33e outputs the created maintenance plan and ends the process.

[0091] In this way, the maintenance plan formulation unit 33e determines whether a part whose lifespan has been determined to be NG requires maintenance involving disassembly at the factory. If the part requires disassembly, a replacement remanufactured part is allocated for replacement and recovery of the product. If there is no inventory, a new part is ordered. In either case, the delivery date of the replacement part is confirmed. The maintenance plan formulation unit 33e checks whether other parts will reach the end of their lifespan before the delivery date of the replacement part, and if there are any such parts, it also plans on-site maintenance for those parts. Then, it creates a maintenance work plan based on the delivery date of the replacement part.

[0092] In addition, if a part whose lifespan has been determined to be NG can be maintained on-site, the system checks to see if there are any other parts that need to be collected within six months and will reach the end of their lifespan. If there are any parts that need to be collected, the system returns to the process for parts that require replacement or collection. If not, the system selects target parts based on their estimated remaining lifespan so that other parts that will reach the end of their lifespan within six months can be maintained on-site at the same time. Since the purpose of on-site maintenance is to maintain performance until the next collection, rebuilt parts are allocated for on-site replacement. If no applicable parts are available, new parts are ordered. In either case, the delivery date for parts for on-site maintenance is confirmed. Finally, a maintenance plan is output that includes schedules and work details that take delivery dates into account. Used parts replaced during on-site maintenance are either collected at the factory and rebuilt, or sent to the parts manufacturer for remanufacturing.

[0093] 21 is a flowchart showing the procedure for recovering and replacing a pump. The system sequentially executes the following steps S801 to S805. In step S801, the manufacturer's remanufacturing base L3 allocates replacement remanufactured products, and then the process proceeds to step S802. In step S802, the manufacturer's remanufacturing base L3 sells the allocated remanufactured replacement product to the leasing company, specifying the leaser, and then proceeds to step S803. In step S803, the manufacturer's remanufacturing base L3 purchases the pump to be collected from the leasing company and transfers the asset, and then the process proceeds to step S804. In step S804, the manufacturer service base L2 replaces and installs the part and collects the used part, and updates the end user information. Then, the process proceeds to step S805. In step S805, the state estimation evaluator 30 starts remote monitoring and outputs the next maintenance plan, after which the process ends.

[0094] In this way, according to the process shown in Figure 21, a replacement remanufactured product that is compatible with the end user's environment is allocated in advance and sold to the leasing company. As a result, the asset is transferred to the leasing company. The pump to be recovered is also purchased from the leasing company and the asset is transferred. As the pump to be recovered is removed and the replacement remanufactured product is brought in, installed, and put into operation, the end user's information is updated. Remote monitoring begins, and the state estimation evaluator 30 outputs the next maintenance plan.

[0095] 22 is a flowchart showing the procedure of on-site maintenance. The manufacturer service base L2 (specifically, the management terminal 41 of the manufacturer service base L2) and the condition estimation evaluator 30 sequentially execute the following steps S901 to S908. In step S901, the manufacturer service base L2 outputs an instruction to prepare necessary parts, etc. in advance based on the maintenance plan, and then the process proceeds to step S902. In step S902, the manufacturer service base L2 outputs a maintenance instruction to the maintenance personnel to carry out the maintenance on-site, and then the process proceeds to step S903. In step S903, the manufacturer service center L2 inspects the actual machine, and then the process proceeds to step S904.

[0096] In step S904, the manufacturer service base L2 determines whether there are any parts that require maintenance other than those planned based on the inspection results of the actual machine. If there are any parts that require maintenance, the process proceeds to step S905. If there are no parts that require maintenance, the process proceeds to step S906. In step S905, the manufacturer service base L2 carries out maintenance on necessary parts other than those specified in the plan, and the process returns to step S903. In step S906, the manufacturer service base L2 receives the work content and inspection results and updates the information, and then the process proceeds to step S907. In step S907, the state estimation evaluator 30 updates the estimated life data and outputs the next maintenance plan, and then the process proceeds to step S908. In step S908, the state estimation evaluator 30 calculates the amount of CO2 emissions per component related to the current maintenance, updates the cumulative CO2 emissions, and ends the process.

[0097] In this way, based on the maintenance plan created by the maintenance plan creation unit 33e, on-site maintenance is coordinated with the end user, and parts and the like necessary for maintenance are prepared in advance. Then, maintenance is carried out on-site based on the maintenance plan. At this time, inspections are also carried out on areas not included in the plan, and maintenance is carried out if any defects are found. When maintenance is completed, all work details are entered into the system and customer information is updated.

[0098] The condition estimation evaluator 30 immediately updates the estimated lifespan (deterioration state) of all parts based on the updated information and outputs the next maintenance plan. In addition, the condition estimation evaluator 30 immediately calculates the CO2 emissions related to the current maintenance implementation on a part-by-part basis based on the updated information and updates the cumulative COs emissions of the machine.

[0099] 23 is a flowchart showing the processing procedure for pre-remanufacturing evaluation. The manufacturer remanufacturing site L3 (specifically, the management terminal 41 of the manufacturer remanufacturing site L3) and the state estimation evaluator 30 sequentially execute the following steps S1001 to S1007.

[0100] In step S1001, the manufacturer's remanufacturing base L3 reads the operating history and environmental information before collection and the latest data of the state estimation evaluator 30. Then, the process proceeds to step S1002. In step S1002, the manufacturer's remanufacturing base L3 inspects the collected product and disassembles it to check the condition of each part, if necessary. Then, the process proceeds to step S1003. In step S1003, the manufacturer's remanufacturing base L3 determines whether there is a difference between the actual product check result and the output of the condition estimation evaluator 30. If there is a difference, the process proceeds to step S1004. If there is no difference, the process proceeds to step S1006.

[0101] In step S1004, the manufacturer's remanufacturing base L3 analyzes the relationship between the operation history, the environmental information, and the actual product state, and then proceeds to step S1005. Step S1005: Based on the analysis results, the manufacturer remanufacturing base L3 adjusts the estimation process of the state estimation evaluator 30. Then, the process proceeds to step S1006.

[0102] In step S1006, the manufacturer's remanufacturing base L3 updates the status of each part as confirmed information, and then proceeds to step S1007. In step S1007, the condition estimation evaluator 30 outputs the maintenance work content based on the condition of the actual product, and the process ends.

[0103] In this way, the condition of pumps returned to the factory is evaluated by referencing the pre-recovery operating history and environmental information accumulated through remote monitoring. The results of the actual condition check of the returned pump are then compared with the output results of the condition estimation evaluator 30 to check for any discrepancies. If there are significant discrepancies, the relationship between the environmental information, operating history, and the actual product condition is analyzed, and the estimation process of the condition estimation evaluator 30 is adjusted. The output of the condition estimation evaluator 30 is then updated to reflect the results of the actual product check, and is output again as the maintenance work details at the factory, representing the condition before remanufacturing.

[0104] 24 is a flowchart showing the procedure of remanufacturing. The manufacturer remanufacturing site L3 (specifically, the management terminal 41 of the manufacturer remanufacturing site L3) and the state estimation evaluator 30 sequentially execute the following steps S1101 to S1109.

[0105] In step S1101, the manufacturer's remanufacturing base L3 checks the actual product against the maintenance work details output from the state estimation evaluator 30. Then, the process proceeds to step S1102. In step S1102, the manufacturer's remanufacturing base L3 determines whether the part is to be remanufactured or replaced. If it is to be remanufactured, the process proceeds to step S1104. If it is to be replaced, the process proceeds to step S1103. In step S1103, the manufacturer's remanufacturing base L3 determines whether a rebuilt part or a remanufactured part is to be used as the replacement part. If it is a rebuilt part, the process proceeds to step S1105. If it is a remanufactured part, the process proceeds to step S1106.

[0106] In step S1104, the manufacturer's remanufacturing base L3 records the level according to the degree of remanufacturing work, and then the process proceeds to step S1107. In step S1105, the manufacturer's remanufacturing base L3 records the level of the rebuilt part, and then proceeds to step S1107. In step S1106, the manufacturer's remanufacturing base L3 records the level of the remanufactured parts, and then the process proceeds to step S1107.

[0107] In step S1107, the manufacturer remanufacturing base L3 determines whether maintenance has been completed for all target parts. If there are any parts that have not been completed, the process returns to step S1101. If maintenance has been completed for all parts, the process proceeds to step S1108. In step S1108, the manufacturer's remanufacturing base L3 assembles the remanufactured pump device 10. After that, the process proceeds to step S1109. In step S1109, the manufacturer's remanufacturing base L3 records the implementation and results of the shipping inspection, and ends the process.

[0108] In this way, the necessary disassembly is performed based on the maintenance work details for remanufacturing output from the condition estimation evaluator 30, and maintenance is carried out on the relevant parts. Depending on their condition, each part is either remanufactured by disassembly, cleaning, repair, etc., replaced with a rebuilt part, or replaced with a part remanufactured by the parts manufacturer. In the case of part replacement, the replaced used part is either rebuilt in the factory or sent to the manufacturer for remanufacturing. The condition of these remanufactured parts is managed as data, and they are stocked at the factory as replacement parts for on-site maintenance or remanufacturing. The results of maintenance are recorded for each part, distinguishing between remanufacturing, replacement with a rebuilt part, replacement with a remanufactured part, and replacement with a new part, and a level is assigned to the degree of remanufacturing work and the quality of the replaced part, and these are also recorded.

[0109] 25 is a flowchart showing the processing procedure for the post-remanufacturing evaluation. The manufacturer remanufacturing site L3 (specifically, the management terminal 41 of the manufacturer remanufacturing site L3) and the state estimation evaluator 30 sequentially execute the following steps S1201 to S1206.

[0110] In step S1201, the manufacturer's remanufacturing base L3 assigns weights to all parts based on the work content of each part and sets initial values ​​for lifespan estimation. Then, the process proceeds to step S1202. In step S1202, the manufacturer's remanufacturing base L3 compiles the work details of all parts in units of 10 remanufactured pump devices, takes into consideration the degree of maintenance, and classifies them into three grades: A, B, and C. Then, the process proceeds to step S1203.

[0111] In step S1203, the manufacturer's remanufacturing base L3 registers all work details in the database, updates the remanufacturing history, and also registers the remanufacturing grade. Then, the process proceeds to step S1204. In step S1204, the state estimation evaluator 30 updates the estimated lifespan (deterioration state) of all parts and outputs the next maintenance plan. At this time, the standard setting conditions are used as the usage conditions and environmental conditions to be applied. In other words, when creating the next maintenance plan, the usage conditions and environmental conditions are reset to the initial setting values. Then, proceed to step S1205. In step S1205, the manufacturer remanufacturing base L3 calculates and registers, based on the updated information, the amount of CO2 emissions relating to the current remanufacturing maintenance execution for each remanufactured pump device 10. Then, the process proceeds to step S1206. In step S1206, the manufacturer's remanufacturing base L3 updates the cumulative COs emissions of the machine, and ends the process.

[0112] In this way, all parts are weighted by the maintenance work performed during the remanufacturing process, and an initial lifespan estimate is set. If the part is remanufactured, the estimated lifespan is shortened. If the part is replaced with a rebuilt part, the estimated lifespan is set to medium. If the part is replaced with a remanufactured part, the estimated lifespan is set to long. If the part is replaced with a new part, the estimated lifespan is set to the longest. After that, the weights of the work performed on all parts are tallied for each remanufactured pump unit 10, and the parts are classified into grades A to C, taking into account the degree of maintenance. All work is registered, the remanufacturing history is updated, and the grade is registered. The condition estimation evaluator 30 updates the estimated lifespan (deterioration state) of all parts and outputs the next maintenance plan. Based on the updated information, the condition estimation evaluator 30 calculates and registers the CO2 emissions associated with the current remanufacturing maintenance work on a per-unit basis, and also updates the cumulative COs emissions of the unit.

[0113] FIG. 26 shows an example of a configuration in which a manufacturer rents equipment to an end user. In FIG. 26, a manufacturer sales office L7 is located instead of a leasing company. Therefore, the manufacturer enters into a subscription contract with the end user L1 while retaining the remanufactured pump equipment 10 as an asset. The other configurations and operations are the same as those in FIG. 1, so the same components are designated by the same reference numerals and their explanations are omitted.

[0114] As described above, the industrial machinery management system disclosed in the embodiments is an industrial machinery management system that manages identification information of a pump device, which is an industrial machine, in association with operation-related information related to the operation of the industrial machine, and is characterized by comprising: a wear degree estimation unit 33b that estimates a wear degree indicating the degree of deterioration due to use for each part included in the industrial machine based on the identification information of the industrial machine and the operation-related information; a remaining life estimation unit 33d that serves as a condition evaluation unit that evaluates the condition of the industrial machine based on the wear degree of one or more parts included in the industrial machine; a server 20 that serves as a memory unit that stores, for each industrial machine, an equipment evaluation that is the evaluation result of the condition of the industrial machine and the wear degree of one or more parts included in the industrial machine; and a maintenance plan formulation unit 33e that formulates a maintenance plan for the industrial machine based on the wear degree and the equipment evaluation. This configuration and operation allows for appropriate management of the condition and recovery of industrial machines, including remanufactured machines.

[0115] In addition, the industrial machine has an electric motor, a main body powered by the electric motor, and a sensor unit that acquires the state of the entire industrial machine, and uses the information acquired by the sensor unit as the operation-related information.When parts of the recovered industrial machine are replaced, the state evaluation unit reevaluates the state of the industrial machine based on the degree of wear of the parts installed as a result of the replacement, and provides the industrial machine to the user again based on the results of the reevaluation.The parts removed by the replacement are repaired and used as parts for future replacements. This configuration and operation allows industrial machinery and its parts to be effectively recycled and reused.

[0116] In addition, the main body, the electric motor, the control device, the communication equipment and the sensor unit are replaceable units, the parts are included in the units, and the condition evaluation unit evaluates the condition of the units based on the degree of wear of the parts included in the units. This configuration and operation makes it possible to perform maintenance work in which the entire device is collected, as well as maintenance work in which each unit is replaced on-site.

[0117] The industrial machinery is further characterized in that it is loaned to a user for a set loan period, and the maintenance plan formulation unit determines the timing of carrying out maintenance work based on the degree of wear and tear, the equipment evaluation, and the remaining loan period. According to this configuration and operation, since the capabilities of the industrial equipment are provided to the user, rather than the industrial equipment itself, whether the industrial equipment is new or remanufactured can be left out of the user's choice.

[0118] In addition, the maintenance plan formulation unit calculates a maintenance plan that indicates information about parts that require maintenance work when the wear level of at least one of the parts that make up the industrial machinery reaches a predetermined value, and the amount of time until the maintenance work is performed. Specifically, the maintenance plan formulation unit determines whether or not the industrial machinery itself needs to be recalled for maintenance work based on the parts that require maintenance work, and if the industrial machinery itself does not need to be recalled, formulates a plan to perform maintenance work on other parts so that the period until the next maintenance work is at least a specified time after the maintenance work is performed, and if the industrial machinery itself needs to be recalled, determines a date for the recall of the industrial machinery itself and formulates a plan to perform maintenance work on site for the parts that require maintenance work by that date. According to this configuration, an appropriate maintenance plan can be formulated based on the condition of the parts, and industrial machinery and parts can be recycled efficiently.

[0119] The system further includes an abnormality sign detection unit 33c that detects signs of abnormality from the operation-related information, and the maintenance plan formulation unit determines the content of the maintenance work according to the detection result of the signs of abnormality. This configuration and operation allows for efficient countermeasures to be taken before an abnormality actually occurs.

[0120] The maintenance plan formulation unit also determines the content of the maintenance work based on the lifespan of the part determined by the degree of wear. This allows for efficient recycling of each part.

[0121] The condition assessment unit also receives result information when maintenance work is performed on the industrial machine, and updates the wear level of the part. The condition assessment unit updates the equipment assessment of the industrial machine based on the updated degree of wear. The wear degree estimation unit uses a learning model to estimate the wear degree of at least one of the parts that make up the industrial machinery, and the condition evaluation unit obtains the results of directly evaluating the wear degree of the parts of the industrial machinery that have been recovered based on the maintenance plan, and uses the difference between the wear degree evaluated on the direct, actual part and the wear degree estimated by the learning model as training data for updating the learning model. According to this configuration and operation, the degree of wear is estimated using a learning model during operation, and feedback is provided to the learning model after recovery, thereby gradually improving the accuracy of estimating the degree of wear during operation.

[0122] The maintenance plan formulation unit also outputs information about carbon dioxide emissions according to the results of executing the maintenance plan. This makes it possible to demonstrate the effect of reducing environmental impact through recycling.

[0123] In addition, when replacing the industrial machine to be provided to a user, the maintenance plan formulation unit determines, based on the user's operating environment and the remaining rental period, what equipment evaluation of the industrial machine is appropriate for the new industrial machine to be provided as replacement. This allows for efficient use of remanufactured products.

[0124] Furthermore, when the wear level fluctuates at a rate equal to or greater than a predetermined rate, the wear level estimation unit outputs possible causes of the fluctuation based on driving-related information before and after the fluctuation. This provides reference information on the operating conditions, contributes to reducing wear and tear, and enables the formulation of maintenance plans that correspond to the operating conditions after the change.

[0125] 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 pump is exemplified in the above embodiment, other industrial equipment may be used. 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]

[0126] 10: Remanufactured pump device, 11: Pump unit, 12: Motor, 13: Control device, 14: Sensor unit, 15: Communication equipment, 20: Server, 21: Communication unit, 22: CPU, 23: Main storage device, 23a: Device management unit, 23b: Data collection unit, 24: Auxiliary storage device, 24a: Pump management data, 24b: Operation history data, 24c: Maintenance history data, 24d: Abnormality history data, 24e: Environmental information data, 24f: Remanufacturing history data, 24g: Part state estimation data, 30: State estimation evaluator, 31: Communication unit, 33: main memory device, 33a: data acquisition unit, 33b: wear degree estimation unit, 33c: abnormality sign detection unit, 33d: remaining life estimation unit, 33e: maintenance plan formulation unit, 33f: output processing unit, 34: auxiliary memory device, 34a: wear degree estimation model, 34b: abnormality sign detection model, 34c: life prediction model, 41: management terminal, L1: end user, L2: manufacturer service base, L3: manufacturer remanufacturing base, L4: manufacturer server, L5: leasing company, L6: condition estimation evaluation server, L7: manufacturer sales base

Claims

1. An industrial machinery management system that manages identification information of an industrial machine and operation-related information related to operation of the industrial machine in association with each other, a wear degree estimation unit that estimates a wear degree indicating a degree of deterioration due to use for each part included in the industrial machine based on the identification information of the industrial machine and the operation-related information; a condition evaluation unit that evaluates a condition of the industrial machine based on a degree of wear of one or more parts included in the industrial machine; a storage unit that stores, for each of the industrial machines, an equipment evaluation that is an evaluation result of the state of the industrial machine and a wear degree of one or more parts included in the industrial machine; a maintenance plan formulation unit that formulates a maintenance plan for the industrial machinery based on the degree of wear and the equipment evaluation; An industrial machinery management system comprising:

2. The industrial machinery management system according to claim 1, The industrial machine has an electric motor, a main body unit powered by the electric motor, and a sensor unit that acquires a state of the industrial machine, The driving-related information is obtained by the sensor unit. When parts of the recovered industrial machinery are replaced, the condition evaluation unit reevaluates the condition of the industrial machinery based on the degree of wear of the replaced parts, and provides the industrial machinery to the user again based on the results of the reevaluation. The parts removed by the replacement are repaired and used as replacement parts for the next or subsequent replacement. An industrial machinery management system characterized by:

3. The industrial machinery management system according to claim 2, the main body, the motor, the control device, the communication device, and the sensor are replaceable units, The part is included in the unit, The condition evaluation unit evaluates the condition of the unit based on the degree of wear of parts included in the unit. An industrial machinery management system characterized by:

4. The industrial machinery management system according to claim 1, The industrial machine is rented to a user for a set rental period, The maintenance plan formulation unit determines the timing of performing maintenance work based on the degree of wear and tear, the equipment evaluation, and the remaining rental period. An industrial machinery management system characterized by:

5. The industrial machinery management system according to claim 1, The maintenance plan formulation unit calculates a maintenance plan indicating information on parts requiring maintenance work and a time allowance until the maintenance work is performed when a wear degree of at least one of the parts constituting the industrial machine reaches a predetermined value. An industrial machinery management system characterized by:

6. The industrial machinery management system according to claim 5, the maintenance plan formulation unit determines whether or not the industrial machine itself needs to be recalled for maintenance work based on the part requiring maintenance work; If the industrial machine itself does not need to be recalled, a plan is drawn up to carry out maintenance work on other parts so that the period until the next maintenance work is at least a predetermined time after the maintenance work is carried out, If the industrial machine itself needs to be recalled, a date for recalling the industrial machine itself is determined, and a plan is drawn up for on-site maintenance work on parts that require maintenance work by that date. An industrial machinery management system characterized by:

7. The industrial machinery management system according to claim 5, further comprising an abnormality sign detection unit that detects an abnormality sign from the driving-related information; The maintenance plan formulation unit determines the content of the maintenance work according to the detection result of the abnormality sign. An industrial machinery management system characterized by:

8. The industrial machinery management system according to claim 5, The maintenance plan formulation unit determines the content of the maintenance work based on the lifespan of the part determined by the degree of wear. An industrial machinery management system characterized by:

9. The industrial machinery management system according to claim 1, The condition assessment unit receives result information when maintenance work is performed on the industrial machine and updates the wear degree of the part. An industrial machinery management system characterized by:

10. The industrial machinery management system according to claim 9, The condition assessment unit updates the equipment assessment of the industrial machine based on the updated wear degree. An industrial machinery management system characterized by:

11. The industrial machinery management system according to claim 9, the wear degree estimation unit estimates the wear degree of at least one of the components constituting the industrial machine using a learning model; The condition evaluation unit obtains a result of directly evaluating the wear degree of the parts of the industrial machinery collected based on the maintenance plan, and uses a difference between the wear degree evaluated directly on the actual part and the wear degree estimated by the learning model as training data for updating the learning model. An industrial machinery management system characterized by:

12. The industrial machinery management system according to claim 1, The maintenance plan formulation unit outputs information about carbon dioxide emissions according to the execution result of the maintenance plan. An industrial machinery management system characterized by:

13. The industrial machinery management system according to claim 4, When replacing the industrial machine to be provided to a user, the maintenance plan formulation unit determines what equipment evaluation of the industrial machine is appropriate as the industrial machine to be newly provided as replacement, based on the operating environment of the user and the remaining rental period. An industrial machinery management system characterized by:

14. The industrial machinery management system according to claim 1, When the wear level fluctuates by a predetermined rate or more, the wear level estimation unit outputs a candidate cause of the fluctuation from driving-related information before and after the fluctuation. An industrial machinery management system characterized by:

15. a server that manages identification information of industrial machines and operation-related information related to operation of the industrial machines in association with each other, a wear degree estimation step of estimating a wear degree indicating a degree of deterioration due to use for each part included in the industrial machine based on the identification information of the industrial machine and the operation-related information; a condition evaluation step of evaluating a condition of the industrial machine based on a degree of wear of one or more parts included in the industrial machine; a step of associating an equipment evaluation, which is an evaluation result of the state of the industrial machine, with a wear level of one or more parts included in the industrial machine, and storing the association result in a storage device; a maintenance plan formulation step of formulating a maintenance plan for the industrial machinery based on the degree of wear and the equipment evaluation; 1. An industrial machinery management method comprising:

Images