Machine evaluation system and machine evaluation method

Abstract

The present invention addresses the problem of evaluating the state of an industrial machine with high accuracy. This machine evaluation system is characterized by comprising an operation history accumulation unit that accumulates the history of the operation of an industrial machine, a maintenance history accumulation unit that accumulates the history of maintenance work for the industrial machine, and an evaluation unit that evaluates the state of the industrial machine on the basis of the history of the operation and the history of the maintenance work, wherein the evaluation unit outputs, as the result of the evaluation, an intended use after the recovery of the industrial machine.

Description

Machine evaluation system, machine evaluation method

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

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

[0003] JP 2014-153736 A

[0004] The above-mentioned conventional technologies can detect signs of failure in the target equipment. However, they do not take into consideration the disposal of the target equipment. When industrial machinery is discarded, it is collected and disposed of by the manufacturer. If the machine is in good condition at this time, it can be reused by undergoing appropriate maintenance, for example, by selling it as second-hand. Furthermore, even if the machine as a whole is unusable, it may be possible to reuse it by attaching parts in good condition to other equipment. In order to determine how to dispose of collected industrial machinery, it is necessary to evaluate the condition of the industrial machinery with high accuracy. Therefore, the present invention aims to provide a high-accuracy evaluation of the condition of industrial machinery.

[0005] To achieve the above object, one representative machine evaluation system of the present invention comprises an operation history accumulation unit that accumulates the operation history of industrial machinery, a maintenance history accumulation unit that accumulates the history of maintenance work on the industrial machinery, and an evaluation unit that evaluates the condition of the industrial machinery based on the operation history and the maintenance work history, and the evaluation unit outputs the use of the industrial machinery after it is retired as a result of the evaluation.Furthermore, one representative machine evaluation method of the present invention is characterized by including, by a computer, the steps of acquiring the operation history of the industrial machinery to be evaluated, acquiring the maintenance work history of the industrial machinery, evaluating the condition of the industrial machinery based on the operation history and the maintenance work history, and outputting the use of the industrial machinery after it is retired as a result of the evaluation.

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

[0007] Explanatory diagram of machine evaluation in Example 1 Configuration diagram of machine evaluation system in Example 1 Configuration diagram of server Specific examples of various data Example of management screen displayed by management terminal Configuration diagram of evaluation device Flowchart showing processing procedure of evaluation device Explanatory diagram of calculation of assessed value Explanatory diagram of determination of use after collection

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

[0009] 1 is an explanatory diagram of machine evaluation in Example 1. In Example 1, a compressor 10 is the subject of evaluation. A server 20 monitors the states of a plurality of compressors 10. Specifically, the server 20 manages device management data 24a, operation history data 24b, maintenance history data 24c, abnormality history data 24d, environmental information data 24e, etc., for the plurality of compressors 10.

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

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

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

[0013] The evaluation unit 33b evaluates that the first reuse (reuse after performance upgrade) can be offered for sale or subscription, the second reuse (reuse after overhaul) can be offered for subscription, and the third reuse (reuse after maintenance) can be offered for sale.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0031] The data acquisition unit 33a is a processing unit that acquires various data from the server 20. The evaluation unit 33b evaluates the state of the compressor 10 using the data acquired by the data acquisition unit 33a. The evaluation unit 33b outputs the assessment amount and use as the evaluation result. The output processing unit 33c performs processing to display the assessment amount and use output by the evaluation unit 33b on, for example, a display device. The output processing unit 33c may also perform processing to transmit the assessment amount and use output by the evaluation unit 33b to an external device.

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

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

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

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

[0036] The evaluation unit 33b multiplies the base assessed value by a coefficient according to the driving time. For example, if the driving time is 6,000 hours or more, the coefficient is set to 0.5, and if the driving time is 5,000 to 5,999 hours, the coefficient is set to 0.6. The driving time can be obtained from the operation history.

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

[0038] Furthermore, the evaluation unit 33b increases the assessed value under certain conditions. Conditions for increasing the assessed value include, for example, "appropriate ambient temperature," "short cumulative operating time," "low number of alarms and failures," "low load count and load rate," "slow progress of suction filter clogging," and "maintenance contract." The evaluation unit 33b decreases the assessed value under certain conditions. Conditions for decreasing the assessed value include, for example, "high ambient temperature," "long cumulative operating time," "high number of alarms and failures," "high load count and load rate," "slow progress of suction filter clogging," "high fin / motor temperature," "no maintenance history," and "low distribution volume." These conditions can be determined based on, for example, the operation history, maintenance history, abnormality history, and operating environment history of the target device. The presence or absence of a distribution volume may be determined by separately referencing sales records. Although the distribution volume is not related to the condition of the target device itself, if there are many models of the same device in circulation, replacement and parts can be easily obtained, and this can be used to evaluate the target device.

[0039] FIG. 9 is an explanatory diagram for determining the use after collection. Brand new equipment has high value and high reliability. Brand new products are suitable for both sales and provision through subscriptions. Reuse after performance upgrade is when collected equipment is remanufactured (modified) to a configuration that provides higher performance than the initial state and then reused. Reuse after performance upgrade has value and reliability close to that of a new product, making it suitable for both sales and provision through subscriptions. Reuse after performance upgrade is useful in cases where environmental efforts are important. Furthermore, since it can be used for a long period of time, it is useful in cases where product replacement is difficult.

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

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

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

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

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

[0045] Furthermore, the evaluation unit 33b evaluates that the first reuse can be provided either through sales or subscription, the second reuse can be provided through subscription, and the third reuse can be provided through sales. Therefore, it is possible to present the method of providing the industrial machine together with its use.

[0046] The evaluation unit 33b also evaluates the condition of the industrial machinery by using any of the history of abnormalities that have occurred in the industrial machinery, information on the operating environment of the industrial machinery, and the amount of the same model in circulation, thereby making it possible to more appropriately select the use of the industrial machinery after it has been collected.

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

[0048] The present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those including all of the described components. Furthermore, not only can such components be deleted, but also replacement or addition of components is possible. For example, a compressor is illustrated in the above-described embodiments, but pumps, printers, and other fluid machinery may also be used. Furthermore, the items of data can be changed as appropriate, and how the data is used to evaluate the operating and maintenance status can also be changed as appropriate.

[0049] 10: Compressor 20: Server 21, 31: Communication unit 22, 32: CPU 23, 33: Main storage device 23a: Device management unit 23b: Data collection unit 24, 34: Auxiliary storage device 24a: Device management data 24b: Operation history data 24c: Maintenance history data 24d: Abnormality history data 24e: Environmental information data 30: Evaluation device 31: Communication unit 33a: Data acquisition unit 33b: Evaluation unit 33c: Output processing unit 41 to 43: Management terminal

Claims

1. A machine evaluation system comprising: an operation history storage unit that stores the operation history of an industrial machine; a maintenance history storage unit that stores the maintenance work history of the industrial machine; and an evaluation unit that evaluates the state of the industrial machine based on the operation history and the maintenance work history, wherein the evaluation unit outputs, as a result of the evaluation, the use of the industrial machine after recovery.

2. The machine evaluation system according to claim 1, wherein the evaluation unit selects, from among uses including at least any one of a first reuse in which the industrial machine is reused after being changed to a configuration that exhibits higher performance than the initial state, a second reuse in which the industrial machine is returned to a state close to the initial state and reused, a third reuse in which the industrial machine is prepared to an operable state and reused, and parts extraction for utilization in units of parts, the use of the industrial machine after recovery.

3. The machine evaluation system according to claim 2, wherein the evaluation unit evaluates that both sales and provision through subscription are possible for the first reuse, evaluates that provision through subscription is possible for the second reuse, and evaluates that sales are possible for the third reuse.

4. The machine evaluation system according to claim 1, wherein the evaluation unit further uses any one of the history of abnormalities that have occurred in the industrial machine, information on the operating environment of the industrial machine, and the distribution volume of the same model to evaluate the state of the industrial machine.

5. The machine evaluation system according to claim 1, wherein the evaluation unit further outputs, as a result of the evaluation, the appraisal value of the industrial machine.

6. The machine evaluation system according to claim 1, wherein the industrial machine is any one of a compressor, a pump, and a printer.

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

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