Preventive maintenance system

Abstract

Provided is a technology with which it is possible to facilitate the identification of a robot to be inspected and improve the efficiency of inspection and maintenance in a preventive maintenance system that monitors and diagnoses a plurality of robots. A preventive maintenance system 10 comprises: a priority calculation processing unit 21 that determines inspection priorities for a plurality of robots 40; an inspection list notification unit 31 that displays a priority list, which is a list of the determined inspection priorities; and an inspection item notification unit 32 that displays inspection items corresponding to each of the robots 40 indicated in the priority list.

Description

Preventive Maintenance System

[0001] The present disclosure relates to preventive maintenance systems.

[0002] In production systems that use robots, a problem with one robot can lead to a long shutdown of the production line, resulting in significant damage. To avoid such situations, information about robots connected to a network is collected to detect abnormalities, diagnose faults, and predict failures. Examples of preventive maintenance systems that monitor abnormalities and failures in this type of equipment include Patent Documents 1 to 5.

[0003] JP 2023-058849 A JP 2020-086495 A JP 2018-207349 A JP 2014-096019 A JP 61-178160 A

[0004] The present disclosure aims to provide a technology that can simplify the identification of robots that need inspection in a preventive maintenance system that monitors and diagnoses multiple robots, thereby realizing more efficient inspection and maintenance.

[0005] The present disclosure relates to a preventive maintenance system that monitors and diagnoses robots, the preventive maintenance system including a priority calculation processing unit that determines inspection priorities for a plurality of the robots, an inspection list notification unit that displays a priority list that is a list of the determined inspection priorities, and an inspection item notification unit that displays inspection items corresponding to each of the robots displayed on the priority list.

[0006] 1 is a functional block diagram of a preventive maintenance system according to an embodiment of the present invention; FIG. 2 is a schematic diagram showing an example of elements constituting a robot; FIG. 3 is a display example of a priority list by the preventive maintenance system; FIG. 4 is a display example of inspection items by the preventive maintenance system; FIG. 5 is a flowchart showing the flow of preventive maintenance processing by the preventive maintenance system; and FIG. 6 is a flowchart showing the processing flow of setting an item as an inspection target again after a certain time has elapsed.

[0007] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] The present disclosure will be described in detail below with reference to the accompanying drawings. Fig. 1 is a functional block diagram of a preventive maintenance system 10 according to an embodiment of the present invention.

[0008] First, the overall configuration of the preventive maintenance system 10 will be described. The preventive maintenance system 10 is a computer that monitors and diagnoses multiple robots 40. The preventive maintenance system 10 is composed of, for example, a processor such as a central processing unit (CPU) and a storage unit. The processor realizes each function of the preventive maintenance system by executing various programs stored in the storage unit. The storage unit is composed of, for example, read-only memory (ROM), random access memory (RAM), non-volatile memory, a hard disk drive, etc., and stores various types of data.

[0009] The robot 40 is, for example, a six-axis articulated robot that performs predetermined processing on a workpiece. In this embodiment, at least one of the multiple robots 40 is a different model from the others. In the example of FIG. 1, three robots 40 are shown, but the number of robots may be two, four, or more. Furthermore, the robot 40 is not limited to a six-axis articulated robot.

[0010] The robot 40 is connected to the preventive maintenance system 10 via a robot control device 41. The robot control device 41 is a computer that controls the operation of the robot 40 based on a processing program, instructions specified by an operator, and the like.

[0011] FIG. 2 is a schematic diagram showing an example of elements constituting the robot 40. As shown in FIG. 2, the robot 40 has multiple axes as elements, such as a first axis 45, a second axis 46, a third axis 47, etc. Note that the elements shown in FIG. 2 are merely examples, and some may be omitted, or other elements may be added or changed. In this example, the first axis 45 includes elements such as a reducer 45a, a cable 45b, a motor 45c, and a sensor 45d. The second axis 46 includes elements such as a reducer 46a, a cable 46b, a motor 46c, and a sensor 46d. The third axis 47 includes elements such as a reducer 47a, a cable 47b, a motor 47c, and a sensor 47d.

[0012] Next, a description will be given of the configuration of the preventive maintenance system 10. The preventive maintenance system 10 includes a data processing device 20 and a display device 30.

[0013] The data processing device 20 executes various processes for performing preventive maintenance. The data processing device 20 of this embodiment has a priority calculation processing unit 21 that determines inspection priorities (scores) for the multiple robots 40 connected to the preventive maintenance system 10.

[0014] The priority calculation processing unit 21 determines the inspection priority for each of the multiple robots 40 to be monitored based on the elements, operation volume, operation time, etc. of each robot 40. The priority calculation processing unit 21 calculates the inspection priority based on, for example, the lifespan data of the reducers, the amount of movement of the axes, the elapsed time since installation, the operation time, etc. The lifespan data may be calculated, for example, by a simulation based on the rotational speed of the reducer of each axis of the robot 40 and the load on the reducer of each axis.

[0015] The display device 30 outputs images to a display or the like and executes processing for displaying various information related to preventive maintenance to an operator. The display device 30 may display images on its own display, or may display images on an external display or computer.

[0016] The display device 30 of this embodiment includes an inspection list notification unit 31 and an inspection item notification unit 32 .

[0017] The inspection list notification unit 31 generates a priority list indicating the inspection priorities along with the robots 40 to be inspected based on the priorities calculated by the priority calculation processing unit 21 .

[0018] Fig. 3 is an example of a priority list displayed by the preventive maintenance system 10. In Fig. 3, robots 40 to be inspected are displayed in a table format. The priority list in the example of Fig. 3 has a robot selection section 100, a placement information display section 101, a robot number display section 102, a model display section 103, and a priority display section 104.

[0019] The robot selection unit 100 realizes a function for checking the robots 40 that have been inspected. After inspection, the operator selects the robot selection unit 100 and checks the robot, and the check result is reflected in the table. The robots 40 that have been checked in the robot selection unit 100 become the targets for the next inspection (targets for priority calculation). A process may be performed to move the robots 40 that have been checked in the robot selection unit 100 to the bottom of the priority list. In this example, the robot selection unit 100 has set a check for all robots 40 in the priority list, and all robots 40 are targets for inspection (targets for priority calculation).

[0020] The placement information display section 101 is an item that displays placement information of the robot 40. The robot number display section 102 is an item that displays the number assigned to the robot 40. The model display section 103 is an item that displays information indicating the model of the robot 40. The priority display section 104 is an item that displays the priority calculated by the priority calculation processing section 21. In this example, the items are arranged so that the higher you go in the priority display section 104, the higher the inspection priority.

[0021] The inspection item notification unit 32 displays inspection items corresponding to each robot 40 displayed in the priority list. For example, the inspection item notification unit 32 displays inspection items for a robot 40 selected and operated by an operator from among the multiple robots 40 displayed in the priority list. Inspection items are set in advance for each robot 40. Inspection items may be set for each model of robot 40, or may be set individually according to the operating time or the use of the robot 40.

[0022] Fig. 4 is an example of the display of inspection items by the preventive maintenance system 10. In Fig. 4, the inspection items of a certain robot 40 in the priority list are displayed in a table format. The inspection item in the example of Fig. 4 has a check display section 110, an element display section 111, an inspection content display section 112, and a response content display section 113.

[0023] The check display unit 110 realizes a function for checking the elements that have been inspected. After inspection, the operator selects the check display unit 110 and checks it, and the check results are reflected in the table. The robot 40 is excluded from the next inspection target (priority calculation target). A process may be performed to move the robot 40 that has been checked in the check display unit 110 to the bottom of the priority list. In this example, all inspection items are checked in the check display unit 110, indicating that inspection of each element of the robot 40 has already been completed.

[0024] The element display section 111 is an item that displays each element to be inspected by the robot 40. In this example, the element display section 111 displays a reducer, a mechanical cable unit, reducer grease, etc. as examples of elements.

[0025] The inspection content display section 112 is an item that displays the inspection content to be performed for each element. The inspection content display section 112 displays the inspection content for each element. For example, for a reducer, examples of inspections are shown such as vibration, iron powder concentration, and grease leakage. The response content display section 113 is an item that displays the response content if an abnormality is found as a result of the inspection. The response content display section 113 displays specific countermeasures (Suggested Actions) for the abnormality or failure, such as replacing the reducer or grease.

[0026] 4 is merely an example. For example, the check display unit 110 may be omitted from the inspection items.

[0027] Next, the flow of preventive maintenance processing executed by the preventive maintenance system 10 will be described with reference to Fig. 5. Fig. 5 is a flowchart showing the flow of preventive maintenance processing by the preventive maintenance system 10. Note that in the following description, explanations referring to flowcharts are merely examples of the processing flow, and are not limited to this configuration.

[0028] In step S1, the data processing device 20 aggregates data relating to a plurality of robots 40. In this embodiment, the data processing device 20 acquires data relating to the robots 40 via the robot control device 41.

[0029] In step S2, the priority calculation processing unit 21 calculates the priority for each of the multiple robots 40 based on information indicating the operating status for determining the priority from among the aggregated data related to the robots 40. As described above, the information indicating the operating status is the lifespan data of the reducers, the amount of movement of the axes, etc.

[0030] In step S3, the inspection list notification unit 31 creates a priority list showing a list of robots 40 to be inspected arranged in order of priority based on the results of the priority calculation processing unit 21, and displays the list on a screen such as a display. When the operator performs a check operation in the inspection item notification unit 32 to indicate that the inspection is complete, the inspection list notification unit 31 changes the display mode of the priority display unit 104 to a character string indicating that the check has been completed, rather than a numerical value indicating the priority. In addition, a process may be executed to change the display position of checked robots 40 to the bottom of the priority list.

[0031] In step S4, the inspection item notification unit 32 displays on a screen such as a display the inspection items corresponding to the robot 40 selected by the operator from the plurality of robots 40 displayed in the priority list. When the operator performs a check operation on the check display unit 110 to indicate that the inspection is complete while the inspection items are displayed, the inspection item notification unit 32 changes the display state of the check display unit 110 to "checked." In addition, a process may be executed to change the display position of the checked inspection contents to below the inspection items.

[0032] In step S5, when all of the check display sections 110 for the inspection items have been checked, the inspection list notification section 31 changes the display mode of the priority display section 104 of the corresponding robot 40 in the priority list to a string indicating that the item has been checked, rather than a number indicating the priority.

[0033] Furthermore, even if an inspection of the robot 40 or an element of the robot 40 has been completed once, it may be necessary to inspect it again as time passes. The inspection item notification unit 32 of this embodiment executes a process for inspecting the robot 40 again as time passes. Next, this process will be described with reference to FIG. 6 .

[0034] FIG. 6 is a flowchart showing the flow of processing for setting a device as an inspection target again after a certain period of time has elapsed.

[0035] In step S11, the inspection item notification unit 32 acquires inspection completion data. The inspection completion data is, for example, the checked robot 40 for which a check operation has been performed or each element included in the inspection item of the robot 40.

[0036] In step S12, the inspection item notification unit 32 determines whether or not the acquired inspected data contains data for which a certain amount of time has elapsed since inspection. If data for which a certain amount of time has elapsed exists, the inspection item notification unit 32 proceeds to step S13 (step S12; Yes). If data for which a certain amount of time has elapsed does not exist, the inspection item notification unit 32 skips step S13 and returns to step S11 (step S12; No).

[0037] In step S13, the inspection item notification unit 32 sets inspected data for which a certain period of time has elapsed as an object for inspection again. The checks in the robot selection unit 100 of the priority list and the inspection item check display unit 110 are cleared. After the processing of step S13, the processing returns to step S11.

[0038] In this embodiment, the inspection target is automatically reset after a certain period of time has elapsed, but the inspection target may be reset manually by an operator or the like.

[0039] As described above, the preventive maintenance system 10 of this embodiment comprises an inspection priority calculation processing unit 21 that determines the inspection priorities for multiple robots 40 connected to the preventive maintenance system 10, an inspection list notification unit 31 that displays a priority list that is a list of the determined inspection priorities, and an inspection item notification unit 32 that displays inspection items corresponding to each of the robots 40 displayed on the priority list.

[0040] The function for notifying the timing of inspection and maintenance in the prior art processes only information for each individual robot and notifies each robot individually of the inspection items. On the other hand, when inspecting and maintaining robots, performing inspection and maintenance on a single robot at once reduces the labor required. Therefore, when multiple robots are involved, a function that indicates the order in which the robots should be inspected and maintained is useful. In this regard, the preventive maintenance system 10 of this embodiment can identify and display inspection items corresponding to the robots displayed in the priority list. This significantly reduces the time required to understand the different inspection items for each model when inspecting multiple robots 40. The preventive maintenance system 10 of this embodiment can achieve more efficient inspection and maintenance in production sites that manage multiple robots.

[0041] In addition, in this embodiment, the inspection item notification unit 32 has a check function that allows input of the fact that the inspection has been completed.

[0042] This allows you to quickly record that an inspection has been completed, and the list function allows you to check whether or not the inspection has been completed for each inspection item.

[0043] In addition, in this embodiment, the inspection item notification unit 32 has a check function that allows an input that maintenance has been completed.

[0044] This allows you to quickly record that maintenance has been completed, and the list function allows you to check whether maintenance has been completed for each inspection item.

[0045] In addition, in this embodiment, the inspection item notification unit 32 has a function of making the robot 40 and inspection items that have been manually or automatically inspected the target of inspection again or the target of priority calculation.

[0046] This allows items that have already been inspected to be displayed in the priority list or inspection items as items that need to be inspected again, preventing situations where inspections are not carried out once they have been inspected.

[0047] Furthermore, in this embodiment, the inspection item notification unit 32 automatically sets the inspected robot 40 and inspection item as an object for inspection or priority calculation again after a certain period of time has elapsed.

[0048] As a result, the inspected robot 40 or inspection item is added to the list of inspection targets again after a certain period of time has passed, and becomes a target for inspection priority calculation. The inspected robot 40 and inspection item are forcibly returned to the inspection list, and become a target for inspection priority calculation again.

[0049] In addition, in this embodiment, the priority calculation processing unit 21 calculates the priority for each robot 40, and the inspection list notification unit 31 displays a priority list in order based on the priority.

[0050] This allows the priority to be displayed for each robot 40, so that the robots 40 that require inspection can be quickly and easily identified from the priority list.

[0051] In this embodiment, the priority calculation processing unit 21 determines the priority based on the life data of the reducers constituting the robot 40 and the amount of movement of the axes.

[0052] This allows the priority to be determined based on the life data of the reducer and the amount of movement of the shaft.

[0053] In the above embodiment, the priority calculation processing unit 21 is configured to calculate the priority for each robot 40, but this is not limited to this configuration. Next, a modified example in which the priority calculation method is different will be described. Note that in the following description, components that are common or similar to those in the above embodiment will be assigned the same reference numerals and their description may be omitted.

[0054] The priority calculation processing unit 21 of the modified example calculates the priority and displays the order of priority for each element of the robot 40. In the example of Fig. 2, the priority calculation processing unit 21 calculates the priority for each of the first axis 45, the second axis 46, and the third axis 47 of the robot 40.

[0055] The priority calculation processing unit 21 calculates the priority of the first axis 45 based on, for example, the life data of the reducer 45a, which is an element of the first axis 45, and the amount of movement of each axis. Priorities are calculated in a similar manner for the second axis 46 and the third axis 47. Furthermore, priorities are determined for each axis of different robots 40.

[0056] As a result, priorities are determined for each axis of all the robots 40 to be inspected. Then, a priority list for each axis is generated based on the priorities determined by the priority calculation processing unit 21. In this priority list, the axes are displayed in descending order of priority, for example, robot C-axis 1, robot C-axis 3, robot B-axis 2, etc.

[0057] As described above, the priority calculation processing unit 21 in the modified example calculates the priority for each element that constitutes the robot 40, and the inspection list notification unit 31 displays a priority list for each element that constitutes the robot 40. As a result, the priority is displayed for each element that constitutes the robot 40, so that the elements of the robot 40 that require inspection can be quickly and easily identified.

[0058] In a modified example, the elements that make up the robot 40 are axes such as the first axis 45, the second axis 46, and the third axis 47, and the priority is determined for each axis. This makes it possible to grasp the priority for each axis.

[0059] In this modified example, the priority is determined on an axis-by-axis basis, but the priority list may be generated by calculating the priority for each element that constitutes an axis, such as the reducer 45a, cable 45b, motor 45c, sensor 45d, etc.

[0060] The present disclosure is not limited to the above-described embodiments, and includes modifications and improvements within the scope of achieving the object of the present disclosure.

[0061] In the above embodiment, the robot 40 is connected to the preventive maintenance system 10 via the robot control device 41, but this is not limiting and the robot 40 may not be connected to the preventive maintenance system 10. Even for a robot that is not connected to the preventive maintenance system 10, the priority can be calculated by inputting, for example, backup information of the robot into the priority calculation processing unit 21.

[0062] In the above embodiment, the inspection item notification unit 32 is configured to have a check function that allows input of whether an inspection has been completed or whether maintenance has been completed, but this is not limiting. At least one of the inspection list notification unit and the inspection item notification unit may be configured to have a check function that allows input of whether an inspection has been completed or whether maintenance has been completed.

[0063] The following supplementary notes are further disclosed regarding the above-described embodiment and modified examples: (Supplementary Note 1) A preventive maintenance system (10) for monitoring and diagnosing a robot (40), comprising: a priority calculation processing unit (21) that determines inspection priorities for a plurality of the robots (40) connected to the preventive maintenance system (10), an inspection list notification unit (31) that displays a priority list that is a list of the determined inspection priorities, and an inspection item notification unit (32) that displays inspection items corresponding to each of the robots (40) displayed on the priority list.

[0064] (Supplementary Note 2) In the above preventive maintenance system (10), at least one of the inspection list notification unit (31) and the inspection item notification unit (32) has a check function that allows input of the fact that the inspection has been completed.

[0065] (Supplementary Note 3) In the above preventive maintenance system (10), at least one of the inspection list notification unit (31) and the inspection item notification unit (32) has a check function that allows input of the completion of maintenance.

[0066] (Supplementary Note 4) In the above preventive maintenance system (10), the inspection item notification unit (32) has a function of making the robot (40) and the inspection item that have been inspected manually or automatically the object of inspection again or the object of priority calculation.

[0067] (Supplementary Note 5) In the above preventive maintenance system (10), the inspection item notification unit (32) automatically sets the inspected robot (40) and the inspection item as an object for inspection or priority calculation again after a certain period of time has elapsed.

[0068] (Supplementary Note 6) In the above preventive maintenance system (10), the priority calculation processing unit (21) calculates the priority for each robot (40), and the inspection list notification unit (21) displays the priority list in order based on the priority.

[0069] (Supplementary Note 7) In the above preventive maintenance system (10), the priority calculation processing unit (21) calculates a priority for each of the elements (45 to 47, 45a to 45e, 46a to 46e, 47a to 47e) constituting the robot (40), and the inspection list notification unit (31) displays a priority list for each of the elements constituting the robot (40).

[0070] (Supplementary Note 8) In the above preventive maintenance system (10), the elements that make up the robot (40) are axes (45, 46, 47).

[0071] (Supplementary Note 9) In the preventive maintenance system (10), the priority calculation processing unit (21) determines the priority based on life data of the reducer constituting the robot (40) and the amount of movement of the axis.

[0072] 10 Preventive maintenance system 21 Priority calculation processing unit 31 Inspection list notification unit 32 Inspection item notification unit 40 Robot 41 Robot control device

Claims

1. A preventive maintenance system for monitoring and diagnosing robots, comprising: a priority calculation processing unit that determines the priority of inspections for a plurality of said robots; an inspection list notification unit that displays a priority list which is a list of the determined inspection priorities; and an inspection item notification unit that displays inspection items corresponding to each of the robots displayed in the priority list.

2. The preventive maintenance system according to claim 1, wherein at least one of the inspection list notification unit and the inspection item notification unit has a check function that enables input of completion of inspection.

3. The preventive maintenance system according to claim 2, wherein at least one of the inspection list notification unit and the inspection item notification unit has a check function that enables input of completion of maintenance.

4. The preventive maintenance system according to any one of claims 1 to 3, wherein the inspection item notification unit has a function of making the inspected robots and inspection items be targets for reinspection or priority calculation again, either manually or automatically.

5. The preventive maintenance system according to claim 4, wherein the inspection item notification unit automatically sets the inspected robots and inspection items to be targets for reinspection or priority calculation again after a certain period of time has elapsed.

6. The preventive maintenance system according to any one of claims 1 to 5, wherein the priority calculation processing unit calculates the priority on a per-robot basis, and the inspection list notification unit displays the priority list in the order based on the priority.

7. The preventive maintenance system according to any one of claims 1 to 4, wherein the priority calculation processing unit calculates the priority for each element constituting the robot, and the inspection list notification unit displays the priority list for each of the elements constituting the robot.

8. The preventive maintenance system according to claim 7, wherein the element constituting the robot is an axis.

9. The preventive maintenance system according to any one of claims 1 to 8, wherein the priority calculation processing unit determines the priority based on the life data of the speed reducer and the movement amount of the axis constituting the robot.

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