Lubricant sales server and lubricant sales system
The lubricant sales server and system address the challenge of managing lubricant degradation by using network-connected sensors to estimate and notify optimal replacement times, improving efficiency and reducing costs and downtime in industrial machinery.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- COSMO OIL LUBRICANTS CO LTD
- Filing Date
- 2022-06-06
- Publication Date
- 2026-06-04
AI Technical Summary
Managing lubricating oil degradation in industrial machinery is challenging due to its deterioration over time, affecting machinery performance and causing potential production stoppages and economic losses, with current methods relying heavily on manual estimation and costly frequent replacements.
A lubricant sales server and system that connects multiple sales destinations via a network, using sensors to detect lubricating oil properties, estimating deterioration states, and notifying terminals when replacement is necessary, optimizing replacement timing based on sensor data and user databases.
Enables timely and cost-effective lubricant replacements, reducing manual labor, minimizing downtime, and preventing machinery failures by accurately monitoring and predicting lubricant degradation.
Smart Images
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Abstract
Description
Technical Field
[0001] The present disclosure relates to a lubricating oil sales server and a lubricating oil sales system.
Background Art
[0002] Various types of oils are used in industrial machines such as hydraulic pumps and injection molding machines to reduce friction between parts. In this specification, the oil used to properly operate such industrial machines is collectively referred to as lubricating oil.
[0003] In this specification, an industrial machine is a mechanical device installed in a factory or workplace. An industrial machine is also a machine that assists or substitutes for difficult or impossible work for humans at various industrial sites including the chemical industry, construction industry, manufacturing factories, and manufacturing sites. Industrial machines include boilers, prime movers, chemical machines, mining machines, transportation machines, environmental devices, plastic machines, machine tools, industrial robots, wind and hydraulic machines, generators, power transmission devices, and commercial washing machines, and are diverse. For example, as a plastic molding machine, industrial machines include injection molding machines, extrusion molding machines, blow molding machines, compression molding machines, foam molding machines, and vacuum molding machines.
[0004] The lubricating oil used in such industrial machines is also called industrial lubricating oil. Lubricating oils have various types depending on the purpose, such as reducing friction between parts of industrial machines, controlling friction, transmitting power, protecting machines, and insulating. Lubricating oils include hydraulic oils, cylinder oils, general-purpose / multi-purpose oils, gear oils, spindle oils, compressor oils, pump oils, turbine oils, refrigeration oils, heat transfer oils, sliding surface oils, bearing oils, electrical insulating oils, and greases. These lubricating oils have various grades depending on the use environment such as kinematic viscosity and temperature. Thus, the types and properties of lubricating oils also vary depending on the purpose of use and the conditions of use.
[0005] Patent Document 1 discloses a lubricant quality control support system for managing the quality of lubricants whose performance may deteriorate over time, comprising a server, a testing department terminal, and at least one customer service terminal, all connected via a communication line. The customer service terminal receives a test request from a customer and transmits the test request data related to the request to the server for storage. The testing department terminal compares the test sample identification data attached to the test sample sent by the customer with the test request data and customer contract data stored on the server, and stores the test result data of the test sample on the server so that the customer service terminal can inquire about it.
[0006] Patent Document 2 discloses an oil product user information management system that can easily determine environmental impact, including CO2 emissions and fuel consumption. The oil product user information management system comprises an information database and a server computer configured to be connectable to client computers via a network. Based on information about oil products registered in the information database, the server computer is configured to calculate at least one of the annual cost reduction amount or the annual CO2 reduction amount and display it on the client computer.
[0007] Patent Document 3 discloses a lubricant sales system suitable for selling lubricants by weight. The lubricant sales system includes a sales unit mounted on a transport vehicle equipped with multiple tanks storing multiple types of lubricants, and a main server that is communicatively connected to the sales unit. The sales unit is detachably connected to one of the multiple tanks and has a discharge mechanism that discharges the lubricant from the tank, and is configured to transmit tank identification information of the tank connected to the discharge mechanism and the amount of lubricant discharged from the tank to the main server. [Prior art documents] [Patent Documents]
[0008] [Patent Document 1] Japanese Patent Publication No. 2007-207104 [Patent Document 2] Japanese Patent Publication No. 2012-185781 [Patent Document 3] Japanese Patent Publication No. 2020-126386 [Overview of the Initiative] [Problems that the invention aims to solve]
[0009] Incidentally, the properties of lubricating oil can deteriorate over time depending on the period of use, the operating rate of the machinery used, and the environment. Furthermore, lubricating oil continues to deteriorate even when not in use. Deterioration of lubricating oil can reduce the performance of industrial machinery (reduced productivity, worsening yield, etc.) and can cause production stoppages due to machinery failures. Such serious problems can result in significant economic losses. It is necessary to replace the lubricating oil before serious problems occur, and lubricating oil management is important. Proper lubrication, leakage prevention, and deterioration countermeasures are important for lubricating oil management. In particular, deterioration countermeasures are crucial for lubricating oil management.
[0010] Lubrication oil degradation can occur, for example, when impurities such as water or wear particles enter the lubricant, when sludge is generated, when the viscosity changes and performance can no longer be maintained, or when the lubricant is oxidized or decomposed by air.
[0011] Proper management of lubricant degradation enables stable operation of industrial machinery, extending its lifespan. Using the appropriate amount of lubricant also reduces manufacturing costs. Smooth operation of industrial machinery leads to energy savings. Thus, managing lubricant degradation can directly impact the productivity of factories and businesses that install industrial machinery.
[0012] However, managing the degradation of lubricating oil is not easy. Frequently extracting lubricating oil from industrial machinery and analyzing its degradation is costly. Management requires manpower, effort, experience, specialized skills (know-how), and expertise. Choosing the optimal lubricating oil for the industrial machinery is also important. Furthermore, changing lubricating oil is costly. Changing lubricating oil requires manpower and is burdensome. During maintenance such as changing lubricating oil, industrial machinery must be shut down, which can result in economic losses for factories and businesses. Therefore, it is preferable to change lubricating oil as few times and at the lowest possible cost.
[0013] Furthermore, it is not easy to estimate the replacement timing while taking into account the deterioration state of the lubricant. Until now, the timing of lubricant replacement has largely depended on the experience of the machine user or the lubricant salesperson, and there has been room for improvement in replacing the lubricant at a more appropriate time.
[0014] This disclosure aims to provide a lubricant sales server and lubricant sales system that can replace lubricants at a more appropriate time. [Means for solving the problem]
[0015] The lubricant sales server disclosed herein is It is connected to multiple sales destinations via a network, and is a lubricant sales server operated by the lubricant distributor, Each sales outlet is: At least one terminal operated by the manager of the sales location, At least one device that uses lubricating oil, The device includes at least one sensor unit that is attached to the device and detects a physical quantity representing the properties of the lubricating oil, The aforementioned sensor unit is A sensor that outputs the physical quantity according to the detection result, The system includes a transmitting unit that transmits, along with the output physical quantity, identification information indicating at least one of the devices to which the sensor unit is attached and the sales location where the device is provided, The aforementioned lubricant sales server, A storage unit that stores a user database for storing the identification information in association with the type of lubricating oil used in the device; A receiving unit that receives the physical quantity and the identification information detected by the sensor unit via the network; A sales destination specifying unit that specifies the sales destination from the identification information based on the user database; An oil type specifying unit that specifies the type of lubricating oil from the identification information based on the user database; An estimation unit that estimates the deterioration state of the lubricating oil based on the specified oil type and the physical quantity; A communication unit that, when the estimated deterioration state satisfies a predetermined condition, transmits a notice to that effect to the terminal of the specified sales destination via the network. It is provided with.
[0016] The lubricating oil sales system of the present disclosure is Connected to a plurality of sales destinations via a network, the lubricating oil sales server according to any one of claims 1 to 6, operated by the lubricating oil supplier; At each sales destination, at least one sensor unit attached to at least one device that uses lubricating oil and detects a physical quantity representing the properties of the lubricating oil; At each sales destination, at least one terminal that is operated by the administrator of the sales destination, receives information indicating that the deterioration state of the lubricating oil satisfies a predetermined condition from the lubricating oil sales server, and outputs the information. It is provided with.
Effect of the Invention
[0017] According to the present disclosure, it is possible to provide a lubricating oil sales server and a lubricating oil sales system that can replace lubricating oil at more appropriate timing.
Brief Description of the Drawings
[0018] [Figure 1] FIG. 1 is an overall configuration diagram of a lubricating oil sales system according to an embodiment of the present disclosure. [Figure 2]Figure 2 is a block diagram of the lubricant sales system. [Figure 3] Figure 3 is a flowchart of the processes performed by the lubricant sales server. [Figure 4] Figure 4 shows an example of a user database owned by a lubricant sales server. [Figure 5] Figure 5 is a schematic diagram showing the change in the acid value of lubricating oil over time. [Figure 6] Figure 6 is a flowchart showing the process performed by the lubricant sales server to identify potential dates for lubricant replacement. [Modes for carrying out the invention]
[0019] The embodiments of this disclosure will be described below with reference to the drawings. For the sake of clarity, the description of components having the same reference numeral as those already described in the description of the embodiments will be omitted.
[0020] Figure 1 is an overall configuration diagram of a lubricant sales system 1 according to an embodiment of the present disclosure. As shown in Figure 1, the lubricant sales system 1 includes a lubricant sales server 2 connected to factories X, Y, and Z via a network N. The lubricant sales system 1 further includes at least one device 3 that uses lubricant, installed in each factory, at least one sensor unit 4 attached to the device 3, and at least one terminal 5 that outputs information received from the lubricant sales server 2. Factories X, Y, and Z are examples of sales destinations.
[0021] Lubricant sales server 2 is operated by the lubricant supplier. The lubricant supplier sells lubricants used in the equipment 3 installed in each factory. The equipment 3 installed in multiple factories is diverse, and the lubricant supplier handles a wide variety of lubricants suitable for each piece of equipment 3. Details of lubricant sales server 2 will be described later.
[0022] Device 3 is an industrial machine that uses lubricating oil, and includes, for example, an injection molding machine, a turbine, and a hydraulic pump. In this example, factory X is equipped with one injection molding machine 3A as device 3. Factory Y is equipped with multiple industrial machines as device 3, including injection molding machines 3A, 3B, and 3C. Factory Z is equipped with an injection molding machine 3C and a turbine 3D as device 3. Although the injection molding machine 3A in factory X and the injection molding machine 3A in factory Y are the same type of industrial machine, they use different types of lubricating oil. The injection molding machine 3A in factory X and the injection molding machine 3C in factory Z are different types of industrial machines, and they use different types of lubricating oil. Note that factory Z is geographically close to factory X.
[0023] Sensor unit 4 is configured to detect a physical quantity representing the properties of the lubricating oil used in device 3. For example, sensor unit 4 is attached to a tank that stores lubricating oil used in injection molding machine 3A at factory X, and detects the physical quantity of lubricating oil stored in the tank. Details of sensor unit 4 will be described later.
[0024] Terminal 5 is a device operated by the manager of the corresponding factory. Terminal 5 may be, for example, a computer with a display unit, or a portable information device with a display unit, such as a smartphone or tablet. Terminal 5 is configured to receive information regarding the deterioration status of lubricating oil from the lubricating oil sales server 2 and output this information. As an output format, Terminal 5 may, for example, display the information from the lubricating oil sales server 2 on the display unit of Terminal 5. The output format of Terminal 5 may also be print or notification.
[0025] Next, we will explain the configuration of the lubricant sales system 1. Figure 2 is a block diagram of lubricant sales system 1. In Figure 2, factory X is shown as an example of a sales destination. The configurations of factories Y and Z are the same as those of factory X, so their explanation is omitted.
[0026] As shown in Figure 2, factory X is equipped with a sensor unit 4 attached to an injection molding machine 3A. The sensor unit 4 is configured to detect a physical quantity representing the properties of the lubricating oil used in the injection molding machine 3A. The sensor unit 4 has at least one sensor 41 and a transmitting unit 42.
[0027] Sensor 41 is configured to output a physical quantity corresponding to the detection result. Sensor 41 may detect and output multiple physical quantities of the lubricating oil. Sensor unit 4 may have multiple sensors. For example, it is preferable that sensor 41 includes at least one of the following: a sensor that outputs a signal corresponding to the acid value of the lubricating oil, a sensor that outputs a signal corresponding to the kinematic viscosity of the lubricating oil, a sensor that outputs a signal corresponding to the water concentration of the lubricating oil, and a sensor that outputs a signal corresponding to the impurity concentration of the lubricating oil.
[0028] The transmitting unit 42 is configured to transmit to the lubricant sales server 2, along with the physical quantity output by the sensor 41, identification information indicating at least one of the injection molding machine 3A to which the sensor unit 4 is attached and the factory X where the injection molding machine 3A is located. The communication means of the transmitting unit 42 may be either wired or wireless. The transmitting unit 42 may transmit the physical quantity and identification information to the lubricant sales server 2 via communication equipment in factory X that is connected to the sensor unit 4 by wire. The transmitting unit 42 transmits the physical quantity and identification information to the lubricant sales server 2 periodically, such as every hour, every week, or every month. Alternatively, the transmitting unit 42 may be configured to transmit the physical quantity and identification information to the lubricant sales server 2 whenever it receives an inquiry signal from the lubricant sales server 2.
[0029] As shown in Figure 2, the lubricant sales server 2 includes a control unit 21 and a storage unit 22. The control unit 21 includes a receiving unit 211, a sales destination identification unit 212, an oil type identification unit 213, an estimation unit 214, and a communication unit 215. The storage unit 22 includes a user database 221, an oil type degradation database 222, and a schedule ledger 223.
[0030] First, let's explain the configuration of the memory unit 22. The user database 221 stores identification information indicating at least one of the injection molding machine 3A to which the sensor unit 4 is attached, and the factory X where the injection molding machine 3A is installed, associating the factory X where the injection molding machine 3A is installed with the type of lubricating oil used in the injection molding machine 3A. Details of the user database 221 will be described later.
[0031] The oil type degradation database 222 stores information about the degradation functions of lubricants handled by lubricant suppliers. The degradation function takes physical quantities representing the properties of the lubricant as input variables and shows the change in the properties of the lubricant over time. In the degradation function, there may be a single physical quantity as a variable, or there may be multiple physical quantities as variables. When the type of lubricant is specified, the oil type degradation database 222 is referenced to identify the degradation function that indicates the degradation state of that lubricant. By inputting the physical quantities output by the sensor 41 as input variables to the identified degradation function, the change in the properties of the lubricant used in the injection molding machine 3A over time, i.e., the degradation state, is quantitatively calculated.
[0032] The schedule ledger 223 includes a customer schedule ledger 224 and a supplier schedule ledger 225. The customer schedule ledger 224 stores at least one of the business days of each customer factory, or the working days or schedules of the person in charge of the equipment 3 at each factory. The supplier schedule ledger 225 stores at least one of the business days of the supplier of the lubricating oil, or the working days or schedules of the person in charge of the supplier's equipment 3. For example, the customer schedule ledger 224 stores the schedule of person S in charge of injection molding machine 3A at factory X, on a daily basis. The supplier schedule ledger 225 stores the schedule of person T in charge of injection molding machine 3A at the supplier, on a daily basis. In this example, the lubricating oil sales server 2 can extract dates that are convenient for both person S at factory X and person T at the supplier by referring to the customer schedule ledger 224 and the supplier schedule ledger 225. In this example, the lubricant sales server 2 may extract schedules based on the business days of each factory and distributor, rather than the schedule of the person in charge.
[0033] Next, the various components of the control unit 21 will be described. The receiving unit 211 is configured to receive physical quantities and identification information transmitted by the transmitting unit 42 of the sensor unit 4 via the network N (Figure 1). The received physical quantities and identification information are transmitted to the sales destination identification unit 212, the oil type identification unit 213, and the estimation unit 214.
[0034] The customer identification unit 212 is configured to identify the customer based on the user database 221 and the identification information received by the receiving unit 211. As described above, the user database 221 stores identification numbers and customer information in association, so the customer identification unit 212 can identify factory X as the customer by referring to the user database 221. If the identification information includes information indicating factory X, the customer identification unit 212 may identify factory X as the customer by referring to the identification information. The specific operation of the customer identification unit 212 will be described later.
[0035] The oil type identification unit 213 is configured to identify the type of lubricating oil from the identification information received by the receiving unit 211, based on the user database 221. As described above, the user database 221 stores identification numbers and lubricating oil types in association, so the oil type identification unit 213 can identify the oil type by referring to the user database 221. The specific operation of the oil type identification unit 213 will be described later.
[0036] The estimation unit 214 is configured to estimate the deterioration state of the lubricating oil based on the oil type deterioration database 222, the oil type identified by the oil identification unit 213, and the physical quantities received by the receiving unit 211. As described above, the oil type deterioration database 222 stores the oil type of lubricating oil and its deterioration function in association with each other. Therefore, the estimation unit 214 can estimate the deterioration state of the lubricating oil by referring to the oil type deterioration database 222 to identify the deterioration function and inputting the physical quantities received by the receiving unit 211 as input variables. The specific operation of the estimation unit 214 will be described later.
[0037] The communication unit 215 is configured to transmit a message to the terminal 5 of the identified customer factory X via the network N (Figure 1) if the deterioration state of the lubricant, as estimated by the estimation unit 214, meets predetermined conditions. The person in charge S at the customer factory X can check the terminal 5 to understand the deterioration state of the lubricant being used.
[0038] (First Embodiment) Next, we will explain the processes performed by the lubricant sales server 2. Figure 3 is a flowchart of the process performed by the lubricant sales server 2. As shown in Figure 3, first the receiving unit 211 of the lubricant sales server 2 receives identification information indicating at least one of the injection molding machine 3A and factory X, along with the physical quantity of lubricant output by the sensor 41, from the transmitting unit 42 of the sensor unit 4 installed in factory X (S1).
[0039] When the receiving unit 211 receives identification information, the customer identification unit 212 refers to the user database 221 and identifies factory X as the customer based on the received identification information (S2). Furthermore, the oil type identification unit 213 refers to the user database 221 and identifies that the type of lubricating oil used in the injection molding machine 3A of factory X is MGX-B2 based on the received identification information (S3). In this example, the customer is identified (S2) and then the oil type is identified (S3), but the order of these steps may be reversed.
[0040] Here, we will explain the details of user database 221. Figure 4 shows an example of the user database 221. As shown in Figure 4, the user database 221 stores information about the factory that is the customer and information about the lubricant used at that factory in association with each other. For example, the user database 221 stores the correspondence between user ID, customer name, contact person name, contact information, customer address, type of oil used, manufacturer and model of the equipment used, start date of lubricant use, data update date, and various physical quantities representing the properties of the lubricant. Note that in Figure 4, for the sake of drawing, only some of the data as various physical quantities are displayed, but in reality, multiple data for each physical quantity are stored in the user database 221, from the first data received by the receiving unit 211 from the transmitting unit 42 to the latest data. Alternatively, the user database 221 may be configured to include a first database that stores the user ID, the name of the customer, the name of the person in charge, contact information, the address of the customer, the type of oil used, the manufacturer and model of the equipment used, the start date of lubricant use, and the data update date, and a second database that stores the user ID, the type of oil used, the manufacturer and model of the equipment used, the date and time of receipt, and various physical quantities on the date of receipt.
[0041] The User ID is a number that identifies the factory to which the product is sold. The Customer Name is the name of the company that operates the factory. The Contact Person Name is the name of the person in charge who manages the equipment that uses lubricating oil at the factory. The Contact Information field stores the contact details for the person in charge, specifically their email address. The Address is information indicating the location of the factory. The Type of Lubricant Used is the type of lubricating oil used. The Equipment Manufacturer is the name of the company that manufactured equipment 3, which is installed at the factory and uses lubricating oil. The Equipment Model is the model number of equipment 3 that uses lubricating oil. The Lubricating Oil Use Start Date is the date when equipment 3 began using lubricating oil. The Data Update Date is the date when the physical quantity of lubricating oil was detected by sensor unit 4 and updated in user database 221. Physical quantities representing the properties of lubricating oil include, for example, acid value, kinematic viscosity, water concentration, impurity concentration, and other physical quantities. The User ID is an example of identification information indicating the customer to which equipment 3 is installed. The Equipment Model is an example of identification information indicating equipment 3 to which sensor unit 4 is attached.
[0042] For example, the user ID for factory X is 001358, and factory X is operated by XXX Manufacturing. At factory X, the person in charge of managing injection molding machine 3A is S, and their contact information is ***@***. Factory X is located in Kawasaki City, Kanagawa Prefecture. The type of lubricant used for injection molding machine 3A is MGX-B2. The company that manufactured injection molding machine 3A is AAA, and the model number of injection molding machine 3A is AX-V8. The date on which the use of lubricant in injection molding machine 3A began was May 30, 2016, and the data update date on March 20, 2022, when the information on each physical quantity of the lubricant was updated, is also included.
[0043] For example, when the receiving unit 211 of the lubricant sales server 2 receives user ID 001358 as identification information, the customer identification unit 212 refers to the user database 221 and identifies XXX Manufacturing Co., Ltd. as the customer name corresponding to user ID 001358 (S2 in Figure 3). Furthermore, the oil type identification unit 213 refers to the user database 221 and identifies MGX-B2 as the oil type used corresponding to user ID 001358 (S3 in Figure 3).
[0044] The items in the user database 221 shown in Figure 4 are examples. The user database 221 may contain further information, or it may contain only some of the items shown in Figure 4.
[0045] In the case of factory X in this example, where there is only one injection molding machine 3A that uses lubricating oil, the lubricating oil sales server 2 can identify the sales destination and the type of lubricating oil by referring to at least one piece of information: the model number of the injection molding machine 3A and the user ID of factory X. On the other hand, in the case of factories Y and Z, where there are multiple devices 3 within a single factory, it is preferable that the identification information includes both the model number of each device 3 to which the sensor unit 4 is attached and the user ID of the factory where the device 3 is installed.
[0046] Returning to Figure 3, we will continue the explanation of the processes performed by the lubricant sales server 2. The estimation unit 214 estimates the deterioration state of the lubricating oil based on the oil type identified by the oil type identification unit 213 and the physical quantities of the lubricating oil received by the receiving unit 211 (S4). For example, based on the identified oil type MGX-B2, the estimation unit 214 identifies the deterioration function corresponding to oil type MGX-B2 stored in the oil type deterioration database 222. Furthermore, the estimation unit 214 inputs the received physical quantities of the lubricating oil as input variables to the identified deterioration function and quantitatively calculates the properties of the lubricating oil. In this way, the estimation unit 214 estimates the deterioration state of the lubricating oil used in the injection molding machine 3A of factory X based on the obtained calculation results.
[0047] The estimation unit 214 estimates the deterioration state of the lubricating oil and determines whether the estimated deterioration state meets predetermined conditions (S5). If the deterioration state meets the predetermined conditions (YES in S5), it transmits this information to the communication unit 215. The communication unit 215 transmits the fact that the deterioration state of the lubricating oil meets the predetermined conditions to the terminal 5 of factory X via the network N (Figure 1) (S6), and the lubricating oil sales server 2 terminates processing. On the other hand, if the deterioration state does not meet the predetermined conditions (NO in S5), the lubricating oil sales server 2 returns to processing S1. Details of the transmission to the terminal 5 of factory X (S6) will be described later.
[0048] Next, we will explain the specific conditions for the deterioration state. Figure 5 is a schematic diagram showing an example of the change in the acid value of lubricating oil over time. As shown in Figure 5, the day on which the injection molding machine 3A began using the lubricating oil is defined as the start date. The acid value of the lubricating oil on the start date is defined as the initial value. As the number of days of use increases from the start date, the acid value of the lubricating oil decreases once from the initial value due to the effects of antioxidants and corrosion inhibitors contained in the lubricating oil. As the number of days of use increases further from the start date, the acid value of the lubricating oil increases due to reactions with oxygen in the air, and continues to rise above the initial value.
[0049] The replacement deadline is defined as the number of days from the initial value until the first threshold, which is estimated to be higher than the initial value, is reached. The replacement deadline is the day when the deterioration of the lubricating oil being used has progressed to the point where the deteriorated lubricating oil may adversely affect the injection molding machine 3A. In other words, the first threshold is a physical quantity of the lubricating oil (in this case, the acid value) that indicates that the lubricating oil has deteriorated to the point where the device 3 will not be able to perform its intended function unless it is replaced, and it is an arbitrary value set by the lubricating oil supplier.
[0050] Furthermore, the day on which the acid value of the lubricant is estimated to fall below the first threshold, which is the second threshold, is designated as the recommended replacement start date. The recommended replacement start date is the start of the period on which lubricant replacement is recommended, as although the deterioration of the lubricant being used is progressing, it is unlikely that the deteriorated lubricant will immediately have an adverse effect on the injection molding machine 3A. The period between the recommended replacement start date and the replacement deadline is designated as the recommended lubricant replacement period. In other words, the second threshold is a physical quantity of the lubricant that indicates that the lubricant has deteriorated to the point where it should be replaced soon, and it is an arbitrary value set by the lubricant supplier.
[0051] In this example, the deterioration status of the lubricating oil indicates the remaining period until the lubricating oil replacement deadline. For example, for lubricating oil type MGX-B2, the acid value at which the replacement deadline is reached is 0.3 mgKOH / g (first threshold), and that date is September 30, 202X. The acid value at which the recommended replacement start date is reached is 0.2 mgKOH / g (second threshold), and that date is September 1, 202X. The recommended replacement period is 30 days, from September 1 to September 30, 202X. If sensor unit 4 detects the acid value of the lubricating oil used in injection molding machine 3A installed in factory X on September 10, 202X, the deterioration status of the lubricating oil will be indicated as the remaining period until the replacement deadline of September 30, i.e., 20 days. Note that the acid value is merely an example of how to determine the replacement deadline or the recommended replacement start date, and is not limited to these values. Similarly, the dates and number of days for the exchange deadline, recommended exchange start date, and recommended exchange period are merely examples and are not limited to these.
[0052] If the properties of the lubricating oil are not monitored over time, even if it is detected that the acid value of the lubricating oil has decreased from its initial value to a lower value Q, it is difficult to determine whether this deterioration occurs at timing Q1, before the acid value has decreased completely, or at timing Q2, after the acid value has decreased completely. In this case, it becomes difficult to estimate the deterioration state of the lubricating oil. In contrast, the sensor unit 4 in this example is attached to the injection molding machine 3A and monitors the changes in the properties of the lubricating oil used over time, thereby enabling a more accurate estimation of the deterioration state of the lubricating oil.
[0053] Next, we will explain in detail the transmission (S6 in Figure 4) of the process executed by the lubricant sales server 2 to terminal 5 of factory X. Figure 6 is a flowchart for identifying candidate dates for lubrication oil replacement. As shown in Figure 6, first the control unit 21 of the lubrication oil sales server 2 identifies the recommended replacement period for lubrication oil from the recommended replacement start date and replacement deadline date (S61).
[0054] Next, the control unit 21 identifies a convenient date SS for the person in charge S at factory X, the customer, based on the customer schedule ledger 224 (S62). As mentioned above, the customer schedule ledger 224 stores the schedule of the person in charge S of the injection molding machine 3A at factory X for each day, so the control unit 21 can identify a convenient date SS for the person in charge S by referring to the customer schedule ledger 224. Changing the lubricating oil requires temporarily stopping the operation of the injection molding machine 3A. For this reason, the control unit 21 needs to refer to the customer schedule ledger 224 to identify a date SS.
[0055] Furthermore, the control unit 21 identifies a convenient date TS for the sales representative T based on the sales representative schedule ledger 225 (S63). As described above, the sales representative schedule ledger 225 stores the schedule of the sales representative T for the injection molding machine 3A for each day, so the control unit 21 can identify a convenient date TS for the sales representative T by referring to the sales representative schedule ledger 225. To change the lubricant, it is necessary to transport the new lubricant directly to the factory X. For this reason, the control unit 21 needs to identify a date TS by referring to the sales representative schedule ledger 225.
[0056] The control unit 21 determines whether there are any common days between the schedule SS, which is convenient for person in charge S, and the schedule TS, which is convenient for person in charge T, within the specified replacement recommendation period (S64).
[0057] If there is a common date (YES in S64), the control unit 21 identifies this common date as a candidate replacement date (S65). If there are multiple common dates, the control unit 21 identifies all of the common dates as multiple candidate replacement dates. Then, the communication unit 215 of the lubricant sales server 2 sends a message to the terminal 5 of factory X stating that the lubricant has deteriorated and that one or more identified candidate replacement dates have been identified (S66), and terminates the process. On the other hand, if there is no common date (NO in S64), the communication unit 215 of the lubricant sales server 2 sends a message to the terminal 5 of factory X stating that the lubricant has deteriorated and that no candidate replacement dates could be identified (S67), and terminates the process.
[0058] In this example, the control unit 21 identifies the recommended replacement period (S61), the schedule SS (S62), and the schedule TS (S63) in that order, but the order of these is not particularly limited. For example, the control unit 21 may identify the schedule SS (S62), then the schedule TS (S63), and then identify the recommended replacement period (S61).
[0059] As explained above, in this example, the lubricant sales server 2 uses a sensor unit 4 attached to the injection molding machine 3A to monitor the deterioration status of the lubricant used in the injection molding machine 3A. Therefore, the deterioration status of the lubricant can be grasped more accurately. Furthermore, the lubricant sales server 2 receives identification information indicating either the injection molding machine 3A or factory X directly from the sensor unit 4, along with the physical quantities detected by the sensor unit 4. As a result, the sales representative T does not need to visit factory X to check the deterioration status of the lubricant, thus achieving labor savings.
[0060] The lubricant sales server 2 can estimate the deterioration state of the lubricant from the received physical quantity and identification information by referring to the user database 221. Therefore, the deterioration state of the lubricant can be calculated quantitatively without relying on the experience of the person in charge S at factory X or the person in charge T at the sales company. Furthermore, if the deterioration state of the lubricant meets predetermined conditions, the lubricant sales server 2 sends a notification to the terminal 5 at factory X. As a result, the person in charge S at factory X does not need to worry about the deterioration state of the lubricant or when it needs to be replaced, and can concentrate on manufacturing operations. In addition, the workload of the person in charge T at the sales company, who is responsible for the lubricant used in multiple devices 3 for multiple sales destinations, can also be reduced.
[0061] In this example, the lubricant sales server 2 can predict the deterioration state of the lubricant and prompt replacement at the appropriate time, thereby preventing malfunctions and accidents of the injection molding machine 3A caused by lubricant deterioration. As a result, various costs and losses, including the cost of lubricant replacement, can be minimized.
[0062] In this example, the state of lubricant degradation is defined as the remaining time until the lubricant replacement deadline. By indicating the state of lubricant degradation in terms of the remaining time until the replacement deadline, it is possible to more efficiently encourage lubricant replacement from the person in charge at factory X, S, and the person in charge at the supplier, T.
[0063] In this example, the physical quantity of the lubricant is its acid value. The acid value of the lubricant changes over time, decreasing from its initial value, increasing back to the initial value, and then continuing to increase. The number of days from when the acid value of the lubricant returns to its initial value until it is estimated to reach the first threshold is identified as the replacement deadline. The day on which it is estimated to reach the second threshold, which is lower than the first threshold, is designated as the recommended replacement start date. The period between the recommended replacement start date and the replacement deadline is designated as the recommended replacement period. By determining the replacement deadline, recommended replacement start date, and recommended replacement period based on the changes in the physical quantity of the lubricant over time, it is possible to achieve efficient and waste-free use of the lubricant while providing the person in charge S at factory X and the person in charge T at the distributor with a specific period suitable for lubricant replacement.
[0064] In this example, the physical quantities of the lubricating oil may include its acid value, kinematic viscosity, water content, and impurity concentration. By considering these physical quantities, the deterioration state of the lubricating oil can be more accurately estimated.
[0065] The storage unit 22 of the lubricant sales server 2 in this disclosure stores a customer schedule ledger 224 which includes at least one of the business days of the customer factory X or the working days or schedules of the person in charge of the injection molding machine 3A at factory X, S, and a supplier schedule ledger 225 which includes at least one of the business days of the supplier or the working days or schedules of the person in charge of the injection molding machine 3A at the supplier, T. Based on the customer schedule ledger 224 and the supplier schedule ledger 225, the communication unit 215 sends one or more days within the recommended replacement period that are convenient for both the person in charge at factory X and the person in charge at the supplier, as replacement candidate dates to the terminal 5 at factory X. In this way, the lubricant sales server 2 identifies the replacement candidate dates for the lubricant, so that the person in charge S and the person in charge T do not need to coordinate their schedules with each other, thereby reducing the workload.
[0066] The lubricant sales system 1 in this example is connected to multiple factories via a network N and comprises a lubricant sales server 2 operated by the lubricant supplier, at least one sensor unit 4 attached to at least one device 3 that uses the lubricant at each factory to detect physical quantities representing the properties of the lubricant, and at least one terminal 5 operated by the sales manager at each factory to receive information from the lubricant sales server 2 indicating that the deterioration state of the lubricant meets predetermined conditions and to output the information. As a result, the deterioration state of the lubricant can be grasped more accurately and quantitatively. Furthermore, the workload of the person in charge S at factory X and the person in charge T at the supplier can be reduced.
[0067] In this example, terminal 5 is a device operated by a factory manager, but the form of terminal 5 is not limited to this. For example, terminal 5 may be mounted on the injection molding machine 3A or the sensor unit 4. For example, if terminal 5 is mounted on the injection molding machine 3A, the information regarding the deterioration status of the lubricant transmitted from the lubricant sales server 2 may be displayed on the display unit of the injection molding machine 3A. Similarly, the information regarding the deterioration status of the lubricant may be displayed on the display unit of the sensor unit 4. By outputting information regarding the deterioration status of the lubricant to the injection molding machine 3A or the sensor unit 4 using the lubricant, the person in charge S at factory X can easily check the deterioration status of the lubricant, thereby reducing the workload.
[0068] Terminal 5 may be located outside the factory, rather than inside. For example, terminal 5 may be located in a different location from the factory, such as the manufacturing company's headquarters, technical department, or central control center, and the manager of these facilities may operate terminal 5.
[0069] Furthermore, the change in the acid value of lubricating oil over time is not limited to Figure 5. Depending on the type of lubricating oil, the machinery used, and the operating environment, the acid value of lubricating oil may gradually increase from its initial value and then rise sharply at a certain point. In addition, the acid value of lubricating oil may remain at its initial value and then begin to rise after a certain period of time.
[0070] In this example, we have described a case where there is one person in charge (person in charge S) at the customer factory X, but the number of people in charge is not limited to one. Factory X may have multiple people in charge. In this case, the customer schedule ledger 224 can identify dates that are convenient for each of the multiple people in charge. For example, even if a date is inconvenient for one person in charge, the customer schedule ledger 224 may identify a date that is convenient for another person in charge, and as a result, the control unit 21 can present a larger number of possible replacement dates. Furthermore, if factory X operates 24 hours a day, 7 days a week, the control unit 21 can present a larger number of possible replacement dates.
[0071] Similarly, a vendor may have multiple contact persons (contact person T), not just one. In this case, the vendor schedule ledger 225 can identify dates that are convenient for each of the multiple contact persons. For example, the vendor schedule ledger 225 may identify dates that are convenient for other contact persons even if they are inconvenient for one contact person, and as a result, the control unit 21 can present a larger number of possible replacement dates. Furthermore, if the vendor operates 24 hours a day, 7 days a week, the control unit 21 can present an even larger number of possible replacement dates.
[0072] The physical quantities that describe the properties of a lubricating oil may include not only acid value and kinematic viscosity, but also color, pH (hydrogen ion concentration), dielectric constant, conductivity, and temperature.
[0073] The color of lubricating oil can be expressed using ASTM colors. ASTM colors are numerical values that represent the hue of lubricating oil. ASTM colors are expressed as the intensity of the hue by comparing a sample in a standard test tube with a standard color glass, and are divided into 16 steps in increments of 0.5 from lightest to darkest. ASTM colors are usually observed visually, and if the color of the sample is too dark, it may be diluted before measurement. As lubricating oil deteriorates, its color changes. For example, if the color of the lubricating oil becomes two steps darker than its initial color, it may be judged as deteriorated. The color of lubricating oil may also be analyzed quantitatively using absorbance or spectroscopic sensors.
[0074] If the lubricating oil is a flame-retardant working fluid, its degradation can be managed by detecting its pH and pre-alkalinity. As the lubricating oil degrades, its pH decreases and it becomes acidic. The pH of the lubricating oil can be detected in real time using a pH sensor. However, since the pre-alkalinity of the lubricating oil is determined by titration, it may be difficult to manage using a sensor. The pre-alkalinity of the lubricating oil (100% equivalent) can be calculated, for example, by adding 90 ml of water to 10 ml of the sample and titrating it with 0.1 mol / L hydrochloric acid until the pH value reaches 5.5.
[0075] The deterioration of lubricating oil can be managed by detecting its base number. The base number is a collective term for the total base number and the strong base number, and is also called the alkali number. The base number is expressed as the number of mg of potassium hydroxide equivalent to hydrochloric acid or perchloric acid required to neutralize the basic components contained in 1 g of sample. Since the base number of lubricating oil is basically determined by titration, management using sensors may be difficult in some cases. Test methods for the base number of lubricating oil may include, for example, the base number test method according to JIS K 2501 (hydrochloric acid method / perchloric acid method), the base number test method by potentiometric titration according to ASTM D4739 (hydrochloric acid method), the base number test method by potentiometric titration according to ISO 3771 (perchloric acid method), and the base number test method by potentiometric titration according to ASTM D2896 (perchloric acid method).
[0076] Alternatively, the deterioration of the lubricating oil can be determined by detecting its dielectric constant and conductivity (electrical conductivity or insulation resistivity). By detecting the dielectric constant and conductivity of the lubricating oil with sensors, the properties of the lubricating oil can be monitored in real time. IoT sensors may also be used. By using these sensors, changes in the properties of the lubricating oil can be detected quickly. To clarify the relationship between the dielectric constant and conductivity of the lubricating oil and the deterioration of the lubricating oil, detection results and data accumulation and learning, such as deep learning using AI, may be used. In the case of an insulating oil, the deterioration of the lubricating oil can be determined by detecting a decrease in insulation resistivity.
[0077] The deterioration of lubricating oil can be managed by detecting its temperature. When lubricating oil deteriorates, its viscosity tends to increase, and friction increases, which tends to raise the temperature of the lubricating oil. The deterioration of lubricating oil can also be determined based on the correlation between the operating conditions of the industrial machinery (e.g., rotational speed in the case of rotating machinery) and the temperature of the lubricating oil. For example, the rotational speed of the industrial machinery and the temperature of the lubricating oil can be detected immediately after the lubricating oil has been changed, and the deterioration of the lubricating oil can be monitored based on these detection results.
[0078] In addition to managing the deterioration of the lubricating oil, the degree of contamination of the filter section, which is installed in industrial machinery and removes contaminants from the lubricating oil, may also be monitored by detecting the differential pressure of the filter section. The density, flash point, kinematic viscosity, viscosity index (VI), pour point, low-temperature viscosity, insoluble components (n-pentane, toluene), sulfated ash, sulfur content, and surface tension of the lubricating oil may also be detected.
[0079] (Variation 1) The lubricant sales server 2 stores the physical quantity of lubricant used at each factory, along with the data update date, in the user database 221 (Figure 4). Based on this stored information, the lubricant sales server 2 can, for example, prompt a change in the lubricant used at another factory Y based on the actual performance of the lubricant used in the injection molding machine 3A at factory X.
[0080] For example, in the case of the lubricant used in injection molding machine 3A at factory X, the period from the start of use to the replacement deadline may be very long. This indicates that using lubricant of type MGX-B2 is appropriate for injection molding machine 3A at factory X, which is manufactured by manufacturer AAA and of type AX-V8. On the other hand, in the case of the lubricant used in injection molding machine 3A at factory Y, the period from the start of use to the replacement deadline may be very short. This indicates that using lubricant of type AAB-A3 is not optimal for injection molding machine 3A at factory Y, which is manufactured by manufacturer AAA and of type AX-V8, compared to the case of injection molding machine 3A at factory X (Figure 4).
[0081] Therefore, in the lubricant sales server 2 of this example, the communication unit 215 may, based on the information stored in the user database 221, send a message to the terminal 5 of factory Y prompting it to change the lubricant used for the injection molding machine 3A from the currently used oil type AAB-A3 to oil type MGX-B2.
[0082] In this way, by utilizing information regarding the deterioration status of the lubricant used in injection molding machine 3A at factory X for injection molding machine 3A at factory Y, it is possible to encourage the person in charge or manager at factory Y to change to a lubricant more suitable for injection molding machine 3A, based on the results from factory X.
[0083] (Modification 2) The lubricant sales server 2 stores the physical quantity of lubricant used in each factory's equipment 3, along with the data update date, in the user database 221 (Figure 4). Based on this stored information, the lubricant sales server 2 may prompt the replacement of the lubricant used in the injection molding machine 3A at factory Y, and simultaneously prompt the replacement of the lubricant used in other injection molding machines 3B used within factory Y (Figure 4).
[0084] For example, suppose the recommended period for changing the lubricating oil used in injection molding machine 3A at factory Y is from June 5th to June 25th, 202X. Also, suppose the recommended period for changing the lubricating oil used in injection molding machine 3B, located within the same factory Y but different from injection molding machine 3A, is from June 15th to June 30th, 202X. Changing the lubricating oil requires temporarily shutting down both injection molding machines 3A and 3B. In particular, temporarily shutting down one industrial machine can affect the entire production line that utilizes that machine.
[0085] Therefore, in the lubricant sales server 2 of this example, based on the information stored in the user database 221, the period from June 15th to June 25th, 202X, which is common to both recommended replacement periods, may be identified as the recommended replacement period. Then, the communication unit 215 may send a message to the terminal 5 of factory Y urging it to replace not only the lubricant of injection molding machine 3A but also the lubricant of injection molding machine 3B within the identified recommended replacement period.
[0086] In this way, by encouraging the replacement of the lubricant used in injection molding machine 3A at factory Y, as well as the lubricant used in injection molding machine 3B within the same factory Y, the impact on the production line at factory Y can be concentrated over a certain period, thereby increasing the overall production efficiency of the factory. Furthermore, the number of times the supplier's representative T has to transport the lubricant to factory Y for replacement, and the associated costs, can also be reduced.
[0087] (Variation 3) The lubricant sales server 2 stores the physical quantity of lubricant used at each factory, along with the data update date, in the user database 221 (Figure 4). Based on this stored information, the lubricant sales server 2 can, for example, prompt the replacement of the lubricant used in injection molding machine 3A at factory X, and also prompt a change in the lubricant used in injection molding machine 3C at factory Z, which is located near factory X.
[0088] For example, suppose the recommended replacement period for the lubricating oil used in injection molding machine 3A at factory X is from October 5th to October 25th, 202X. Factory X is located in Kawasaki City, Kanagawa Prefecture. Suppose the recommended replacement period for the lubricating oil used in injection molding machine 3C at factory Z is from October 15th to October 30th, 202X. Factory Z is also located in Kawasaki City, Kanagawa Prefecture.
[0089] In this situation, the lubricant sales server 2 in this example may, based on the information stored in the user database 221, identify the period from October 15th to October 25th, 202X, as the recommended replacement period, which is common to both recommended replacement periods. Then, the communication unit 215 may transmit the identified recommended replacement period to the terminal 5 of factory X, and also transmit the identified recommended replacement period to the terminal 5 of factory Z.
[0090] In this way, by providing the same recommended replacement period to multiple factories located close to each other, the workload of the sales representative T, who is responsible for transporting the lubricating oil to each factory, can be reduced.
[0091] While embodiments of this disclosure have been described above, it goes without saying that the technical scope of this disclosure should not be interpreted restrictively by the description of these embodiments. These embodiments are merely examples, and it will be understood by those skilled in the art that various modifications to the embodiments are possible within the scope of the invention described in the claims. The technical scope of this disclosure should be determined based on the scope of the invention described in the claims and the scope of its equivalents. [Explanation of symbols]
[0092] 1: Lubricant sales system 2: Lubricant sales server 21: Control Unit 211: Receiving Unit 212: Sales Destination Identification Department 213: Oil type identification department 214: Guessing Department 215: Communications Department 22: Storage part 221: User Database 222: Oil Type Degradation Database 223: Schedule Ledger 224: Sales Destination Schedule Ledger 225: Vendor Schedule Ledger 3: Equipment 3A, 3B, 3C: Injection molding machine 3D: Turbine 4: Sensor Unit 41: Sensor 42: Transmitter 5: Terminal S, T: Person in charge Q: Measurement Q1, Q2: Timing X, Y, Z: Factory N: Network
Claims
1. It is connected to multiple sales destinations via a network, and is a lubricant sales server operated by the lubricant distributor, Each sales outlet is: At least one terminal operated by the manager of the sales location, At least one device that uses lubricating oil, The device includes at least one sensor unit that is attached to the device and detects a physical quantity representing the properties of the lubricating oil, The aforementioned sensor unit is A sensor that outputs the physical quantity according to the detection result, The system includes a transmitting unit that transmits, along with the output physical quantity, identification information indicating at least one of the devices to which the sensor unit is attached and the sales location where the device is provided, The aforementioned lubricant sales server, A storage unit that stores the following: a user database that stores the identification information associated with the device, the sales location where the device is installed, and the type of lubricating oil used in the device; and a lubricating oil type degradation database that stores the type of lubricating oil associated with a function that indicates the change in the properties of the lubricating oil over time. A receiving unit that receives the physical quantity and identification information detected by the sensor unit via the network, A customer identification unit identifies the customer from the identification information based on the user database, Based on the user database, an oil type identification unit identifies the type of lubricating oil from the identification information, Based on the aforementioned oil type degradation database, an estimation unit identifies the function from the identified oil type, and by inputting the physical quantity as an input variable into the identified function, estimates the degradation state as a change in the properties of the lubricating oil over time. A lubricant sales server comprising: a communication unit that monitors the estimated deterioration state and, if it is estimated that the physical quantity has reached a threshold and that it is recommended to replace the lubricant, transmits a message to that effect to the terminal of the sales customer identified via the network.
2. The lubricant sales server according to claim 1, wherein the deterioration state is the remaining period from the day the sensor unit detected the physical quantity to the lubricant replacement deadline, which is the day on which the physical quantity is presumed to reach the threshold.
3. The aforementioned physical quantity is the acid value. The number of days from when the acid value decreases from its initial value, then increases, and returns to the initial value, until it is estimated to reach a first threshold higher than the initial value, is defined as the exchange deadline. The day on which the acid value is estimated to fall below the second threshold, which is lower than the first threshold, is designated as the recommended replacement start date. The lubricant sales server according to claim 1, wherein the period between the recommended replacement start date and the recommended replacement deadline date is defined as the recommended replacement period.
4. The lubricant sales server according to claim 1, wherein the physical quantities include the acid value, kinematic viscosity, water content, and impurity content of the lubricant.
5. The storage unit stores a customer schedule ledger including at least one of the customer's business days or the working days or schedules of the customer's representative for the device, and a seller schedule ledger including at least one of the seller's business days or the working days or schedules of the seller's representative for the device. The lubricant sales server according to claim 3, wherein the communication unit transmits to the terminal of the specified customer, based on the customer schedule ledger and the sales source schedule ledger, one or more days within the recommended replacement period that are convenient for the person in charge at the customer and convenient for the person in charge at the sales source, as candidate replacement dates.
6. The terminal is mounted on the device or the sensor unit, as described in claim 1, for the lubricant sales server.
7. A lubricant sales server according to any one of claims 1 to 6, which is connected to multiple sales destinations via a network and operated by the lubricant distributor, At each sales location, at least one sensor unit is attached to at least one device that uses lubricating oil and detects a physical quantity representing the properties of the lubricating oil, A lubricant sales system comprising: at least one terminal operated by the manager of each sales location to monitor the deterioration state of the lubricant, receive information from the lubricant sales server indicating that the physical quantity has reached a threshold and that it is recommended to replace the lubricant, and output the information.