System and method for diagnosing operation of air knocker

Abstract

The present invention relates to a system for diagnosing the operation state of an air knocker having a magnetic piston. The system collects magnetic field change signals generated by an operation of the piston through a magnetic field sensor, and analyzes an operation pattern by optimizing the magnetic field change signals in a control unit. The control unit can determine whether the piston is normal on the basis of the analyzed pattern, and thereby accurately diagnose the operation state of the air knocker.

Description

Air knocker operation diagnosis system and diagnosis method

[0001] The present invention relates to an air knocker operation diagnosis system and method, and more particularly, to a system and method for monitoring the operation of an air knocker in real time to determine whether it is operating normally.

[0002] An air knocker is a device primarily used in industrial processes. It uses air pressure to reciprocate a magnetic piston installed inside, applying shock. The shock generated by the piston serves to dislodge accumulated residue or aggregates within a storage tank or pipeline.

[0003] Air knockers are mainly installed inside storage tanks, silos, or conveying devices that handle powder or granular materials and are used to maintain smooth material flow or prevent clogging.

[0004] In factories, air knockers are often fixed in specific locations on the production floor where the equipment is installed, and workers often have to physically access the device to check whether it is operating.

[0005] In particular, if the distance between the place where the air knocker is installed and the control panel operated by the operator is far, it takes a lot of time to monitor or check for problems when they occur because it is necessary to directly observe whether it is operating normally.

[0006] Additionally, if the air knocker does not operate properly, the worker must go to the site to check the status of the device and manually resolve the problem, which is a hassle.

[0007] This manual inspection method not only reduces work efficiency, but can also lead to long-term process interruptions due to unrecognized problems. In large factories, the impact on productivity can be even more severe.

[0008] To address these issues, a system is needed that can remotely monitor the operating status of air knockers and automatically detect and take action when anomalies occur. This requires a technological solution that reduces operator effort and enables more efficient device maintenance.

[0009]

[0010] The purpose of the present invention is to provide a system and method capable of remotely monitoring the operating status of an air knocker in real time and automatically detecting abnormal operation to quickly respond.

[0011] Additionally, by precisely tracking the movement of the magnetic piston through a magnetic field sensor, it provides a technical means to detect abnormal operation or wear of the device at an early stage and to predict expected errors and maintenance needs in advance.

[0012] The problems to be solved by the present invention are not limited to the technical problems mentioned above, and other technical problems not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

[0013]

[0014] An air knocker operation diagnosis system according to one embodiment of the present invention includes: an air knocker having a magnetic piston; at least one magnetic field sensor attached to the air knocker to collect a magnetic field change signal caused by the operation of the magnetic piston; and a control unit receiving the magnetic field change signal from the magnetic field sensor, wherein the control unit optimizes the magnetic field change signal, determines an operation pattern of the magnetic piston based on the optimized magnetic field change signal, and determines whether the operation of the magnetic piston is normal based on the determined operation pattern.

[0015] The above control unit can amplify the collected magnetic field change signal and remove noise from the amplified magnetic field change signal to optimize the magnetic field change signal.

[0016] The above-determined motion pattern may include at least one of data peak occurrence information, data peak intensity information, or data peak-to-peak interval information.

[0017] The above-determined normality may include at least one piece of information on normal operation, abnormal operation, aging, or signs of failure of the air knocker.

[0018] A plurality of magnetic field sensors are included, and the control unit can optimize the magnetic field change signal by synthesizing at least two magnetic field change signals measured by at least two magnetic field sensors among the plurality of magnetic field sensors.

[0019] The control unit may analyze the operation pattern of the magnetic piston for a preset period of time and set the operation pattern as a normal pattern. If the operation pattern of the magnetic piston analyzed in real time is identical to the normal pattern, it may be determined as normal operation. If the operation pattern of the magnetic piston is different from the normal pattern, it may be determined as abnormal operation.

[0020] If the above control unit determines that the above operation is abnormal, the above control unit may further include a notification unit that provides a notification to the user.

[0021] A communication unit that transmits whether the control unit determines whether the result is normal; and a monitoring unit that receives the result from the communication unit and displays it on a screen may be further included.

[0022] A user input unit capable of inputting a user command based on whether the screen is normal or not may further include a driving unit for driving a solenoid valve provided in the air knocker to operate the magnetic piston based on the input user command.

[0023] In addition, a method for diagnosing an air knocker operation according to another embodiment of the present invention may include a step of collecting a magnetic field change signal due to an operation of a magnetic piston measured by at least one magnetic field sensor attached to the air knocker; a step of optimizing the collected magnetic field change signal; a step of determining an operation pattern of the magnetic piston based on the optimized magnetic field change signal, and a step of determining whether the operation of the magnetic piston is normal based on the determined operation pattern.

[0024] The above optimizing step may further include a step of amplifying the collected magnetic field change signal and removing noise from the amplified magnetic field change signal.

[0025] The above-determined motion pattern may include at least one of data peak occurrence information, data peak intensity information, or data peak-to-peak interval information.

[0026] The above-determined normality may include at least one piece of information on normal operation, abnormal operation, aging, or signs of failure of the air knocker.

[0027] The above optimization step may further include a step of synthesizing at least two magnetic field change signals measured by at least two magnetic field sensors among a plurality of magnetic field sensors attached to the air knocker.

[0028] The above-described judging step may be performed by analyzing the operation pattern of the magnetic piston for a preset period of time to set the operation pattern as a normal pattern, and if the operation pattern of the magnetic piston analyzed in real time is identical to the normal pattern, it may be determined as normal operation, and if the operation pattern of the magnetic piston is different from the normal pattern, it may be determined as abnormal operation.

[0029] The above judging step may further include a step of providing a notification to the user if the above abnormal operation is determined.

[0030] It may further include a step of receiving the above-determined normality and displaying the continuously received normality.

[0031] It may further include a step of controlling whether a solenoid valve provided in the air knocker is opened based on whether the above-described normal condition is received.

[0032] According to another embodiment of the present invention, an air knocker for diagnosing operation using a magnetic field sensor comprises: a cylinder made of a metal material; a magnetic piston built into the cylinder; a solenoid valve coupled to an upper portion of the cylinder and selectively supplying or discharging compressed air; a driving unit for driving the solenoid valve; at least one magnetic field sensor attached to the outside of the cylinder and collecting a magnetic field change signal caused by the operation of the magnetic piston; and a control unit for controlling the magnetic field sensor and the driving unit, wherein the control unit optimizes the magnetic field change signal, determines an operation pattern of the magnetic piston based on the optimized magnetic field change signal, and determines whether the operation of the magnetic piston is normal based on the determined operation pattern.

[0033] It may further include a communication unit capable of remotely transmitting whether the control unit is normal or not.

[0034]

[0035] According to at least one embodiment of the present invention, it is possible to accurately determine whether an air knocker is normal by detecting and analyzing the operation of a magnetic piston in real time through a magnetic field sensor.

[0036] According to at least one embodiment of the present invention, the operating status of the air knocker can be remotely monitored and a quick response can be made by transmitting the normality determined by the control unit to an external system through the communication unit.

[0037] According to at least one embodiment of the present invention, the operation pattern of a magnetic piston can be analyzed to predict aging conditions or signs of failure in advance, thereby performing preventive maintenance and minimizing process interruptions.

[0038] Further scope of the applicability of the present invention will become apparent from the detailed description below. However, since various modifications and variations within the spirit and scope of the present invention will become apparent to those skilled in the art, it should be understood that the detailed description and specific examples, such as preferred embodiments of the present invention, are given by way of example only.

[0039] FIG. 1 is a block diagram of an air knocker operation diagnosis system according to one embodiment of the present invention.

[0040] Figure 2 illustrates an air knocker according to one embodiment of the present invention.

[0041] FIG. 3 is a drawing for explaining a step of optimizing a magnetic field change signal in an air knocker operation diagnosis method according to an embodiment of the present invention.

[0042] FIG. 4 is a drawing showing examples of abnormal operation in an air knocker operation diagnosis method according to an embodiment of the present invention.

[0043] Figure 5 is a flowchart of an air knocker operation diagnosis method according to one embodiment of the present invention.

[0044] Figure 6 is a flowchart for explaining a method for diagnosing the normal operation of an air knocker according to an embodiment of the present invention.

[0045]

[0046] Hereinafter, embodiments disclosed in this specification will be described in detail with reference to the attached drawings. Regardless of the drawing numbers, identical or similar components are given the same reference numbers and redundant descriptions thereof will be omitted.

[0047] The suffixes "module" and "part" used in the following description are assigned or used interchangeably solely for the convenience of writing the specification, and do not in themselves have distinct meanings or roles. Furthermore, when describing the embodiments disclosed herein, if a detailed description of a related known technology is deemed to obscure the gist of the embodiments disclosed herein, the detailed description will be omitted.

[0048] In addition, the attached drawings are only intended to facilitate easy understanding of the embodiments disclosed in this specification, and the technical ideas disclosed in this specification are not limited by the attached drawings, and should be understood to include all modifications, equivalents, or substitutes included in the spirit and technical scope of the present invention.

[0049] Terms that include ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by these terms. These terms are used solely to distinguish one component from another.

[0050] When a component is referred to as being "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components intervening. Conversely, when a component is referred to as being "directly connected" or "connected" to another component, it should be understood that there are no other components intervening.

[0051] Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0052] In this application, terms such as “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but should be understood not to exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0053] Hereinafter, an air knocker operation diagnosis system according to an embodiment of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a block diagram of an air knocker operation diagnosis system according to an embodiment of the present invention. FIG. 2 is a diagram of an air knocker operation diagnosis system according to an embodiment of the present invention.

[0054] Referring to FIG. 1, an air knocker operation diagnosis system according to one embodiment of the present invention may include an air knocker, a magnetic field sensor, a control unit, a communication unit, and a factory control device.

[0055] Although the magnetic field sensor, control unit, and communication unit are shown as independently provided, the scope of the present invention is not limited thereto, and the magnetic field sensor may be integrally included in the air knocker, and the control unit and communication unit may be included in the air knocker or the factory control device.

[0056] As described above, an air knocker is a device mainly used in industrial processes. It uses air pressure to reciprocate a magnetic piston installed inside, thereby applying impact and knocking down accumulated residue or coagulation within a storage tank or pipeline.

[0057] An air knocker according to one embodiment of the present invention may include a magnetic piston, a solenoid valve, and a driving unit for driving the solenoid valve.

[0058] The magnetic piston may be installed inside the metal cylinder of the air knocker. However, if the metal cylinder is magnetic, it may interfere with the measurement of the movement of the magnetic piston.

[0059] Magnetic pistons generate a strong impact force through a reciprocating motion driven by pneumatic pressure. This impact force is transmitted to storage tanks, pipelines, or hoppers, dissolving internal material agglomeration and preventing clogging.

[0060] A solenoid valve can control the airflow within the air knocker's cylinder. The solenoid valve is mounted on the top of the cylinder and can selectively supply or exhaust compressed air. This allows the magnetic piston to operate at an appropriate speed and cycle.

[0061] The driving unit is a control mechanism that drives the solenoid valve and can control the opening and closing of the valve by receiving an external control signal.

[0062] Referring to FIG. 2, the magnetic field sensor may be attached to the exterior of the cylinder. The magnetic field sensor may be provided independently of the air knocker and attached to the cylinder, or may be provided as an integrated device with the air knocker.

[0063] The magnetic field sensor is attached to the outside of the cylinder and can collect signals by detecting changes in the magnetic field caused by the movement of the magnetic piston inside.

[0064] The magnetic piston possesses its own magnetism, and as the piston moves within the cylinder, the position and strength of the magnetism changes. This magnetic field change is transmitted to the outside of the cylinder where the sensor is located, and the sensor detects it and converts it into an electrical signal.

[0065] The sensor may contain a sensing element, such as a Hall effect element or fluxgate, capable of precisely detecting changes in a magnetic field. This sensing element can detect changes in the strength and direction of the magnetic field, converting the movement of the magnetic piston into a time-dependent signal.

[0066] In this way, a magnetic field sensor such as a Hall sensor can be used to measure the movement of a magnetic piston, but if the material of the cylinder in which the magnetic piston is built is a magnetic material such as iron, the magnetic field change may be distorted or reduced, making the measurement inaccurate.

[0067] To address this issue, an air knocker operation diagnostic system according to one embodiment of the present invention may utilize multiple magnetic field sensors. Measurements may be performed using signals collected from each of the multiple magnetic field sensors.

[0068] That is, the collected signal can be amplified and filtered through the sensor's built-in circuitry, and then transmitted to the control unit for data processing. The control unit can analyze this signal to determine the piston's operating status, such as its position, speed, and movement cycle. This will be described in detail later with reference to Figure 3.

[0069] The magnetic field sensor can transmit the collected magnetic field change signal to the control unit.

[0070] In the case where multiple magnetic field sensors are provided, at least two or more magnetic field change signals measured by at least two of the multiple magnetic field sensors can be transmitted to the control unit.

[0071] The control unit can control the driving unit, magnetic field sensor, communication unit, monitoring unit, and user input unit of the air knocker. This control unit (550) can include at least one processor (or controller). Furthermore, in terms of hardware, the control unit (550) can include at least one CPU. Of course, it can also include an AP (application processor), microcomputer, IC, ASIC (application specific integrated circuit), or other hardware-based processor.

[0072] The control unit may be provided independently, or may be provided as an air knocker, a factory control unit, or both.

[0073] The control unit optimizes the magnetic field change signals collected from the magnetic field sensor and analyzes the magnetic piston's operating patterns to determine whether they are normal. It also transmits the analyzed information to external systems, alerts the user in the event of abnormal operation, and controls the air knocker's operation when necessary.

[0074] The control unit will be described in detail with reference to the drawings described below.

[0075] The communication unit can transmit the operating status, normality, and related data of the magnetic piston, as determined by the control unit, to an external system, or receive control commands or feedback signals from the external system. This provides an interface for remotely monitoring and controlling the operating status of the air knocker.

[0076] The communication unit may be provided independently, or may be incorporated into the air knocker, the plant control unit, or both.

[0077] The communication unit supports data exchange between the control unit, monitoring unit, and user input unit. It transmits information analyzed by the control unit, such as the magnetic piston's operating status, normal operation, aging status, and signs of failure, to the monitoring unit for visual display. This allows users to monitor the air knocker's operating status in real time.

[0078] Additionally, by receiving user commands, feedback signals, or control commands transmitted from the user input unit and transmitting them to the control unit, the device allows users to remotely adjust the operation of the Air Knocker or activate specific functions. This allows operators to check the device's status and take immediate action when necessary, even when physically distant from the Air Knocker.

[0079] Additionally, the communication unit transmits and receives data based on wireless communication, wired communication, or network protocol, and may include data encryption and error detection functions to ensure the stability and reliability of the signal.

[0080] The monitoring unit can monitor the operating status of the air knocker in real time and provide visual information to the user. The monitoring unit can be installed independently or incorporated into a factory control system that controls the entire plant.

[0081] The monitoring unit can display information on the air knocker, such as normal operation, abnormal operation, aging, and signs of failure, based on data transmitted from the control unit. This information can be presented in a visually intuitive manner, allowing operators to immediately understand the air knocker's status.

[0082] The monitoring unit and user input unit may be provided independently or integrated within the same factory control unit, allowing the user to monitor and control the status of various facilities within the factory from a single interface.

[0083] In particular, even when the air knocker and monitoring unit are physically far apart, data can be transmitted quickly and reliably through the communication unit, allowing information to be displayed in real time.

[0084] In addition to continuously displaying the air knocker's status, the monitoring unit can also provide users with warning messages or notifications when abnormal operation is detected. This allows operators to immediately recognize air knocker problems and input appropriate response commands through the user input unit.

[0085] The monitoring unit provides a user-friendly graphical interface that displays not only summary information on operating status but also detailed data. For example, it can visualize and provide users with detailed diagnostic data such as peak occurrence information, data intervals, and operation pattern analysis results.

[0086] This allows operators to efficiently manage the overall plant situation and effectively determine when maintenance or manual intervention of the air knocker is required. This will be described later with reference to Figure 4.

[0087] The user input section is a component included in the factory control unit designed to allow the user to remotely control or adjust the operation of the air knocker.

[0088] The user input unit receives user commands through various interfaces such as a touch screen, button panel, keyboard, or voice command input device, and transmits the input data to the control unit so that it can be reflected in the operation of the air knocker.

[0089] For example, a command entered through a user input unit is transmitted to a control unit through a communication unit. The control unit processes the received command and transmits a signal to the actuator unit, and the actuator unit operates a solenoid valve in response to the signal.

[0090] The solenoid valve controls the movement of the magnetic piston by regulating the flow of compressed air under the control of the actuator. This allows the magnetic piston to reciprocate, generating the impact force the air knocker is designed to generate, thereby smoothing the flow of material or clearing blockages.

[0091] The user input section allows remote input of operating commands even from a location physically distant from the air knocker, allowing the operator to perform control without having to physically go to the location where the air knocker is installed.

[0092] Additionally, commands entered in the user input section can be recorded and used to analyze later maintenance records or process management data.

[0093] The factory control unit centrally manages and controls various facilities within the factory, including the air knocker. It is located in a location, such as a control room, for easy operator operation. This unit can be physically separated from the air knocker and, in addition to remotely controlling the air knocker, can comprehensively monitor and control various facilities within the factory.

[0094] Referring to FIG. 2, a plurality of magnetic field sensors (200a, 200b) may be attached to the outer surface of the cylinder of an air knocker including a cylinder and a solenoid valve. As illustrated, for example, two magnetic field sensors may be attached at different locations, and it is of course also possible to attach more than that number of sensors.

[0095] Multiple magnetic field sensors can be connected to a control unit and transmit information. This connection can be wired or wireless. The control unit can receive multiple magnetic field change signals measured from each of the multiple magnetic field sensors.

[0096] At this time, the control unit can obtain information on the operation of the air knocker by optimizing the magnetic field change signal based on multiple magnetic field change signals. This will be described below with reference to FIG. 3.

[0097] FIG. 3 is a drawing for explaining a step of optimizing a magnetic field change signal in an air knocker operation diagnosis method according to an embodiment of the present invention.

[0098] Fig. 3 (a) may represent, for example, a magnetic field change signal measured by a first magnetic field sensor (200a). Fig. 3 (b) may represent, for example, a magnetic field change signal measured by a second magnetic field sensor (200b). Fig. 3 (c) may represent an optimized signal obtained by synthesizing a magnetic field change signal measured by a first magnetic field sensor and a magnetic field change signal measured by a second magnetic field sensor.

[0099] Figure 3(a) shows a magnetic field change signal measured by the first magnetic field sensor (200a), which includes peaks that change according to the movement of the magnetic piston. The signal measured by the first sensor shows a signal intensity change of approximately 7.4% compared to the average value, which indicates the degree of magnetic field change detected according to the movement of the piston.

[0100] Fig. 3(b) shows a signal measured by the second magnetic field sensor (200b), which is measured at a complementary position to the first sensor, and has an opposite shape when compared to Fig. 3(a). The peak of the signal measured by the second magnetic field sensor shows a signal intensity change of approximately 11.2% compared to the average value. Since the second sensor detects a change in the magnetic field at a different position from the first sensor, the signals measured by each sensor may show differences in the position and intensity of the peak.

[0101] Figure 3(c) shows an optimized signal synthesized from the measurement data of the first and second sensors. This process calculates or adds the difference between the two signals, thereby amplifying the signal strength and reducing noise, thereby increasing signal reliability.

[0102] Referring to Figure 3 (c), the signal generated as a result of synthesis exhibits a signal intensity change of approximately 77.9% compared to the average value, indicating that the magnetic piston's movement can be detected with greater sensitivity than the sensor signal alone. This optimized signal is analyzed by the control unit and used to determine the piston's movement pattern and whether it is operating normally.

[0103] It can also reduce offset values ​​that can act as noise. Signals measured individually from each sensor can contain significant offsets from a reference value (e.g., the sensor's default output) due to environmental influences.

[0104] For example, referring to FIG. 3(a) and FIG. 3(b), the average value of the signal observed from the sensor may be located between 1500 and 2000, so even if the deviation of the signal is close to the reference value, the absolute offset may be large.

[0105] However, referring to Fig. 3(c), the signals from the two sensors can be synthesized to reconstruct the signal around a reference value (a value close to 0), and in this process, the offset can be reduced from approximately 0 to 500. This reduces the signal's reference deviation, allowing the pure signal intensity to be more prominent.

[0106] By synthesizing multiple magnetic field change signals in this way, the accuracy of signal interpretation can be improved by minimizing noise effects. Furthermore, the accuracy can be further enhanced as the number of magnetic field sensors increases.

[0107] FIG. 4 is a diagram illustrating examples of abnormal operation in a method for diagnosing air knocker operation according to an embodiment of the present invention. It also illustrates examples of screens displayed on a monitoring unit according to each embodiment.

[0108] Air knocker operation diagnosis can be performed based on commands from a control unit (e.g., PLC, PC, etc.), and may be performed only when a specific command is issued. Furthermore, the air knocker operation status can be continuously monitored and diagnosed regardless of the presence or absence of commands.

[0109] The operation pattern analyzed to determine the operation status of the air knocker may include at least one of data peak occurrence information, data peak intensity information, or data peak-to-peak interval information.

[0110] Data peak occurrence information indicates when signal peaks occur during piston movement and return, which can be used to identify the start and end points of piston movement.

[0111] The intensity information of the data peaks represents the intensity of the peaks occurring in the motion and return signals, and can reflect the motion energy or impact force of the piston.

[0112] The data peak-to-peak interval information represents the time interval between an action peak and a return peak or the period between consecutive actions, and can be used as an indicator to determine whether the periodic movement of the piston is normal.

[0113] Figure 4(a) can represent a signal that clearly demonstrates the movement and return of the magnetic piston during normal operation. This signal is an optimized signal based on data collected from a magnetic field sensor, with unnecessary noise removed and the signal intensity amplified.

[0114] The signal shown in Fig. 4(a) can be displayed on the monitoring screen in real time, and the operator can intuitively check the operating status of the air knocker through this.

[0115] Referring to Figure 4 (a), for example, under normal operating conditions, a peak occurring when the piston moves and a peak in the opposite direction occurring when returning can be clearly distinguished. The interval and intensity between the two peaks have a consistent pattern, and this pattern can be set as the normal pattern based on data analyzed over a preset period of time.

[0116] The control unit can determine whether the air knocker is operating normally by comparing the piston movement pattern collected in real time with this normal pattern.

[0117] If the magnetic piston's movement pattern, as analyzed in real time, is identical to the normal pattern, the control unit can determine that the air knocker is operating normally. Conversely, if the real-time movement pattern differs from the normal pattern, the control unit can determine that the air knocker is operating abnormally and provide a notification or take maintenance measures.

[0118] In normal operation, the observation of a constant and repetitive signal as in Fig. 4(a) may indicate that the air knocker is functioning stably.

[0119] Figure 4(b) illustrates a case where the piston is not operating. In this case, since there is no movement of the magnetic piston, no magnetic field change detectable by the magnetic field sensor occurs.

[0120] The fluctuations in the magnetic field generated when the magnetic piston moves are converted into signals by the sensor, but if the piston does not move or return at all, these fluctuations do not occur and therefore no peak signals are observed.

[0121] Under normal operating conditions, a consistent pattern of peak signals is generated according to the piston's movement and return. However, in cases where no signal is present at all, as shown in Figure 4(b), the control unit can determine that the real-time analyzed movement pattern is completely different from the normal pattern.

[0122] This is a case where both the motion and return peaks corresponding to the normal pattern have disappeared, and the control unit determines this as an abnormal operating state.

[0123] In such situations, the control unit can provide an alarm to alert the user immediately. For example, the monitoring screen can display a warning message such as "Air knocker not operating" or "Abnormal operating condition." Additionally, visual and auditory warnings can be provided, such as changing the screen color to red or sounding an alarm.

[0124] Additionally, abnormal conditions can be transmitted to a higher-level system to remotely identify problems or alert workers. Additionally, alarms can include specific information, such as the air knocker's location and time of occurrence, to help workers quickly identify problems and take action.

[0125] Figure 4(c) may represent an abnormal condition in which a delay occurs during piston return. In this case, both the operating peak and the return peak are observed, but the return peak is shifted further back than the normal position.

[0126] This may indicate anomalies in the piston's return process, mechanical wear, or a problem with the pneumatic system.

[0127] In this situation, not only the presence or absence of a signal or its intensity, but also the time interval between the motion peak and the return peak becomes an important criterion for judgment.

[0128] Under normal operating conditions, the interval between the two peaks is constant, which is established as a normal pattern. However, if the return peak appears late, as shown in Fig. 4(c), the interval between the two peaks becomes abnormally long.

[0129] The control unit can analyze these interval changes to detect that the signals collected in real time are different from the normal pattern and determine that this is an abnormal operating state.

[0130] A delayed return can be caused by factors such as insufficient pressure being supplied when the piston returns, foreign matter accumulating inside the cylinder, or increased friction of the piston itself.

[0131] These analysis results can be used not only to assess the current condition, but also to predict the aging of the piston or signs of failure.

[0132] For example, if a gradual increase or irregular change in the peak-to-peak gap is observed consistently, this may indicate piston wear or a deterioration in the performance of the pneumatic system.

[0133] In this situation, the control unit can display a warning message such as "Piston return delay occurred" on the monitoring screen, and provide a visual warning (e.g., screen color change) and an audible warning so that the operator can immediately recognize the problem.

[0134] Additionally, the interval between two peaks and the return delay time are specifically displayed, allowing operators to assess the severity of the problem and take appropriate action. Abnormal information can also be sent to a higher-level system to remotely report the problem or provide automatic maintenance notifications.

[0135] Figure 4 (d) may represent an abnormal condition in which the magnetic piston operates but does not return. In this case, when the magnetic piston initially operates, a peak in the operation is detected by the magnetic field sensor, but the peak signal in the opposite direction that should occur during the piston return process is not observed.

[0136] This is a situation where the piston's return motion is not performed properly and is different from the normal pattern, and the control unit can determine this as an abnormal operating state.

[0137] The absence of a piston return signal can be caused by a variety of factors. For example, mechanical wear within the piston, insufficient air pressure, or a malfunctioning solenoid valve can interfere with the return motion. This prevents the magnetic field change required for the return process from occurring, preventing the sensor from detecting it.

[0138] In a normal pattern, the piston's movement and return are accompanied by regular, repeating peak signals. However, if the return signal is absent, the normal pattern and the real-time signal pattern become distinctly different. The control unit can analyze these differences, determine an abnormality, and provide an immediate alarm.

[0139] In this situation, various alarm formats can be provided. For example, the monitoring screen may display warning messages such as "Air knocker not operating" or "Abnormal operating condition," or a more specific warning message such as "Piston return failure" may be displayed. The screen may flash red or a visual warning icon may be added to highlight the abnormal condition.

[0140] Additionally, it can sound an alarm to alert workers to the problem immediately, or send an abnormal condition to a higher-level system to remotely transmit an alert.

[0141] Additionally, the alarm may include information about the location of the piston where the problem occurred, when the abnormality first occurred, and the possible cause.

[0142] In this way, the normality determined by the control unit may include information on normal operation, abnormal operation, aging, or signs of failure by evaluating the operating status of the air knocker from various angles.

[0143] In normal operation, the operation and return peaks are observed at regular intervals and intensities, indicating that the air knocker is functioning stably.

[0144] On the other hand, an abnormal operating condition is determined when a signal different from the normal pattern is observed, such as when the peak disappears or the interval changes abnormally during piston movement or return.

[0145] Additionally, a gradual increase in peak-to-peak spacing or a decrease in peak intensity can be used as an indicator of aging, indicating problems such as wear or deterioration in pneumatic system performance.

[0146] Based on this information, you can detect signs of failure in advance and plan necessary maintenance, thereby increasing equipment reliability and minimizing process interruptions.

[0147] Figure 5 is a flowchart of an air knocker operation diagnosis method according to one embodiment of the present invention.

[0148] First, a magnetic field change signal resulting from the movement of the magnetic piston is collected via a magnetic field sensor (S5100). This signal detects the magnetic field change resulting from the movement of the magnetic piston in real time and is transmitted to the control unit. The collected signal undergoes various processing steps for optimization in subsequent stages.

[0149] The collected magnetic field change signal is amplified to a level that can be analyzed (S5300). This step clearly reveals subtle signal changes and contributes to increased signal processing accuracy. The amplified signal then undergoes a process to remove unnecessary noise in the next step.

[0150] Noise is removed from the amplified signal to obtain pure data (S5400). This process uses filtering technology to minimize signal distortion and organizes the signal into a form suitable for comparison with normal operating patterns.

[0151] Additionally, a process of synthesizing and integrating signals collected from multiple sensors is performed (S5200). This step compensates for data differences between sensors and integrates them into a single, highly reliable signal. The order of steps S5200 to S5400 may vary depending on the system configuration.

[0152] Based on the noise-removed and synthesized signal, the control unit analyzes the magnetic piston's operating pattern (S5500). This process extracts the operating pattern by analyzing the signal peak locations, intervals, and intensity associated with the piston's movement and return. The extracted pattern can be set as the normal pattern for comparison.

[0153] The results of the motion pattern analysis are compared with normal patterns to determine whether the air knocker is functioning normally (S5600). If the pattern matches the normal pattern, the air knocker is considered to be operating normally. If the pattern differs, it is considered to be operating abnormally. This allows for the identification of signs of abnormal operation, aging, or failure.

[0154] The determined normal status is provided to the user via a display (S5700). The display visually displays information on normal operation, abnormal operation, or specific abnormal conditions, allowing the operator to easily check the status of the air knocker.

[0155] The user can input control commands for the air knocker via the input unit (S5800). These commands are used to control the operation of the magnetic piston by operating the solenoid valve via the control unit. This method enables interaction between the user and the system, allowing real-time adjustments to the air knocker's status.

[0156] FIG. 6 is a flowchart illustrating a process for determining whether an air knocker operation is normal in a method for diagnosing an air knocker operation according to an embodiment of the present invention.

[0157] First, the magnetic piston's operating pattern is analyzed over a preset period of time and established as a normal pattern (S6100). In this step, based on signal data collected over a set period of time, the piston's operating and return peaks, inter-peak intervals, and intensity are analyzed to establish a reference pattern that defines normal operation. This reference pattern is then used as a criterion for determining normal operation by comparing it with signals collected in real time.

[0158] Next, the magnetic piston's operating pattern is analyzed in real time (S6200). The control unit processes data collected from the sensor to extract the location, interval, and intensity of peak signals generated in real time, and organizes these into a operating pattern. This step is performed to diagnose the current operating status of the air knocker.

[0159] Afterwards, the real-time analyzed pattern is compared with the preset normal pattern to determine whether there is a match (S6300). If the real-time operation pattern is identical to the normal pattern, normal operation is determined (S6400). In this case, the air knocker maintains stable operation without any additional warnings or measures.

[0160] Conversely, if the real-time operation pattern differs from the normal pattern, it is determined as abnormal operation (S6500). This determination is based on signal characteristics that differ from the normal pattern, such as missing peak signals, irregular intervals, and intensity variations.

[0161] If abnormal operation is determined, a notification is provided to the user (S6600). The notification displays a warning message on the monitoring screen or sounds an alarm, allowing the operator to immediately recognize the problem. The notification may include details about the abnormality, such as the location and time of the problem.

[0162] Finally, the solenoid valve is controlled to resolve or respond to the abnormal operating condition (S6700). The control unit sends specific control signals to correct the abnormal condition and can attempt to resolve the problem by stopping or readjusting the air knocker's operation.

[0163] Through this procedure, it is possible to evaluate the normality of the air knocker in real time and provide appropriate notifications and responses when an abnormality occurs.

[0164] It will be apparent to those skilled in the art that the present invention may be embodied in other specific forms without departing from the spirit and essential characteristics of the present invention.

[0165] The above detailed description should not be construed as limiting in any respect and should be considered illustrative only. The scope of the present invention should be determined by a reasonable interpretation of the appended claims, and all modifications within the equivalent scope of the present invention are intended to be included within the scope of the present invention.

Claims

1. Air knocker with magnetic piston; At least one magnetic field sensor attached to the air knocker and collecting a magnetic field change signal caused by the operation of the magnetic piston; Including a control unit that receives the magnetic field change signal from the magnetic field sensor, The above control unit An air knocker operation diagnosis system characterized by optimizing the magnetic field change signal, determining the operation pattern of the magnetic piston based on the optimized magnetic field change signal, and determining whether the operation of the magnetic piston is normal based on the determined operation pattern.

2. In paragraph 1, The above control unit An air knocker operation diagnosis system characterized by amplifying the collected magnetic field change signal and optimizing the magnetic field change signal by removing noise from the amplified magnetic field change signal.

3. In paragraph 1, The above judged movement pattern is An air knocker operation diagnosis system characterized by including at least one of data peak occurrence information, data peak intensity information, and data peak-to-peak interval information.

4. In paragraph 1, Whether the above judgment is normal or not An air knocker operation diagnostic system characterized in that it includes at least one piece of information among information on normal operation, abnormal operation, aging, or failure signs of the air knocker.

5. In paragraph 1, Containing multiple magnetic field sensors, The above control unit An air knocker operation diagnosis system characterized in that it optimizes the magnetic field change signal by synthesizing at least two magnetic field change signals measured by at least two magnetic field sensors among the plurality of magnetic field sensors.

6. In paragraph 1, The above control unit An air knocker operation diagnosis system characterized in that the operation pattern of the magnetic piston is analyzed for a preset period of time to set the operation pattern as a normal pattern, and if the operation pattern of the magnetic piston analyzed in real time is identical to the normal pattern, it is determined as normal operation, and if the operation pattern of the magnetic piston is different from the normal pattern, it is determined as abnormal operation.

7. In paragraph 6, An air knocker operation diagnosis system characterized in that it further includes a notification unit that provides a notification to a user when the control unit determines that the above operation is abnormal.

8. In paragraph 1, A communication unit that transmits whether or not the control unit determines normal; and An air knocker operation diagnosis system characterized by further including a monitoring unit that receives whether the above communication unit is normal and displays it on a screen.

9. In paragraph 8, A user input section that can input a user command based on whether the screen is normal or not; and An air knocker operation diagnosis system further comprising a driving unit that drives a solenoid valve provided in the air knocker to operate the magnetic piston based on the input user command.

10. A step of collecting a magnetic field change signal caused by the operation of a magnetic piston measured by at least one magnetic field sensor attached to the air knocker; A step of optimizing the collected magnetic field change signal; An air knocker operation diagnosis method, comprising: a step of determining an operation pattern of the magnetic piston based on the optimized magnetic field change signal, and determining whether the operation of the magnetic piston is normal based on the determined operation pattern.

11. In paragraph 10, The above optimization steps are An air knocker operation diagnosis method, characterized in that it further includes a step of amplifying the collected magnetic field change signal and removing noise from the amplified magnetic field change signal.

12. In paragraph 10, The above judged movement pattern is An air knocker operation diagnosis method characterized in that it includes at least one of data peak occurrence information, data peak intensity information, and data peak-to-peak interval information.

13. In paragraph 10, Whether the above judgment is normal or not An air knocker operation diagnosis method characterized in that it includes at least one piece of information among information on normal operation, abnormal operation, aging, or failure signs of the air knocker.

14. In paragraph 10, The above optimization steps are A method for diagnosing an air knocker operation, characterized in that it further includes a step of synthesizing at least two magnetic field change signals measured by at least two magnetic field sensors among a plurality of magnetic field sensors attached to the air knocker.

15. In paragraph 10, The above judging steps are An air knocker operation diagnosis method characterized by analyzing the operation pattern of the magnetic piston for a preset period of time and setting the operation pattern as a normal pattern, determining normal operation if the operation pattern of the magnetic piston analyzed in real time is identical to the normal pattern, and determining abnormal operation if the operation pattern of the magnetic piston is different from the normal pattern.

16. In paragraph 15, The above judging steps are An air knocker operation diagnosis method characterized by further comprising a step of providing a notification to a user when the above abnormal operation is determined.

17. In paragraph 10, An air knocker operation diagnosis method further comprising the steps of: receiving the above-determined normal status; and displaying the continuously received normal status.

18. In paragraph 17, An air knocker operation diagnosis method further comprising a step of controlling whether a solenoid valve provided in the air knocker is opened based on whether the above-described normal state is received.

19. Cylinder made of metal; A magnetic piston built into the above cylinder; A solenoid valve coupled to the upper part of the cylinder to selectively supply or discharge compressed air; A driving unit that drives the above solenoid valve; At least one magnetic field sensor attached to the outside of the cylinder and collecting a magnetic field change signal caused by the operation of the magnetic piston; A control unit for controlling the magnetic field sensor and the driving unit is included; The above control unit It is characterized by optimizing the magnetic field change signal, determining the operation pattern of the magnetic piston based on the optimized magnetic field change signal, and determining whether the operation of the magnetic piston is normal based on the determined operation pattern. Air knocker that diagnoses operation using a magnetic field sensor.

20. In paragraph 19, A communication unit capable of remotely transmitting whether or not the control unit is normal; further comprising: Air knocker that diagnoses operation using a magnetic field sensor.

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