Advance replacement timing prediction device

Abstract

[Problem] To predict an advance replacement timing for a replaceable component other than a specific replaceable component. [Solution] This advance replacement timing prediction device determines whether an advance replacement timing has been reached for a replaceable component of a kneading material processing device that is provided with a plurality of replaceable components and that processes a kneading material with the plurality of replaceable components, said advance replacement timing prediction device comprising a determination unit which determines whether an advance replacement timing has been reached for each of the plurality of replaceable components.

Description

Pre-exchange Timing Prediction Device

[0001] The technology of the present disclosure relates to a pre-exchange timing prediction device.

[0002] Patent Document 1 discloses a kneading device including side plates that form a kneading chamber inside, a pair of kneading rotors disposed in the kneading chamber, and a wear detection sensor that detects wear of the kneading rotors.

[0003] Japanese Unexamined Patent Application Publication No. 2020-104436

[0004] However, since the wear detection sensor of the above prior art detects wear of the kneading rotors, the kneading device of the above prior art can only determine wear of the kneading rotors. In this regard, in a kneading device, parts that deteriorate such as wear along with the operation of the kneading device are not only specific replacement parts of the kneading rotors.

[0005] The technology of the present disclosure aims to provide a pre-exchange timing prediction device that can determine whether replacement parts other than specific replacement parts should be replaced.

[0006] A first aspect of the technology of the present disclosure is a pre-exchange timing prediction device that includes a plurality of replacement parts and determines the arrival of the pre-exchange timing of the replacement parts of a kneading material processing device that processes kneading materials with the plurality of replacement parts, and includes a determination unit that determines whether each of the plurality of replacement parts has reached its respective pre-exchange timing.

[0007] In the first aspect of the technology of the present disclosure, since the determination unit determines whether each of the plurality of replacement parts of the kneading material processing device has reached its respective pre-exchange timing, it is possible to determine whether replacement parts other than specific replacement parts should be replaced.

[0008] Figure 1 is a schematic diagram of an example of a kneader 10 according to an embodiment. Figure 2 is a block diagram of the electrical system of an example of a pre-replacement timing prediction device 100. Figure 3 is a diagram showing an example of processing by the CPU 32. Figure 4 is another diagram showing an example of processing by the CPU 32. Figure 5 is a flowchart of an example of a replacement parts replacement processing program executed by the CPU 32. Figure 6 is a flowchart of an example of a pre-replacement timing arrival determination processing program executed by the CPU 32. Figure 7 is a diagram showing the replacement times T1, T2, T3 of a plurality of replacement parts 1 to 3 and the pre-replacement times K1, K2, K3 which are predetermined time before each replacement time. Figure 8 is a diagram showing an example of a kneader 10 in a disassembled state. Figure 9 is a schematic side view of an example of an extruder 100.

[0009] Embodiments of the technology of this disclosure will be described below with reference to the drawings.

[0010] (Configuration) Figure 1 is a schematic diagram of an example of a kneader 10 according to the embodiment. Figure 8 is a diagram showing an example of the kneader 10 in a disassembled state. As shown in Figure 1, the kneader 10 is equipped with a plurality of interchangeable parts 1 to 5 and 7. For example, interchangeable parts 1 to 6 are a pressurizing cylinder 1, a pressurizing lid 2, a blade shaft 3, a bearing 5, a mixing tank 6, a supporter 7, etc. The kneader 10 kneads the material using the above plurality of interchangeable parts 1 to 5 and 7. The front right side (motor 9 side) of the mixing tank 6 is equipped with a side plate 14A attached by a screw 16, and the left side (reversing worm gear 8 side) is equipped with a side plate 14B. The pressurizing cylinder 1 is a cylinder device for applying pressure. By applying uniform pressure to the material, the efficiency of mixing and kneading the material is improved. Hydraulic pressure or pneumatic pressure is used. The pressurizing lid 2 is a lid that covers the top of the mixing tank 6 and applies pressure to the material inside the mixing tank 6. The pressurized lid 2 works in conjunction with the pressurized cylinder 1 to press down on the mixing material from above. The blade shaft 3 uniformly mixes the material in the mixing tank and shears the material in the gap between the blade shaft and the mixing tank. The blade shape or size of the blade shaft 3 varies depending on the properties and purpose of the material being mixed. This ensures uniform mixing and dispersion of the material. The blade shaft 3 rotates and plays a role in mixing the materials. The bearing 5 is a support component that allows the blade shaft 3 to rotate smoothly. It reduces friction, stabilizes the rotation of the shaft, and extends the life of the machine. The bearing 5 minimizes friction between the blade shaft 3 and other structures. The mixing tank 6 is the container into which the material is introduced and mixed. This is where the blade shaft 3 rotates and mixes the material. The shape or size of the mixing tank 6 is designed according to the amount or type of material being processed.

[0011] The kneader 10 is an example of a "kneading material processing device" of the technology disclosed herein.

[0012] The kneader 10 is equipped with a disassembly detection sensor 12A that detects when, for example, the side plate 14A has been disassembled from the mixing tank 6 (see also Figure 8) in order to replace the replacement parts 1 to 5. When the side plate 14A is disassembled from the mixing tank 6, the disassembly detection sensor 12A outputs a disassembly detection signal to the pre-replacement timing prediction device 100 (see also Figure 2). In addition, a supporter 7 is provided between the pressurizing cylinder 1 and the pressurizing lid 2, and a disassembly detection sensor 12B is located inside the supporter 7. The disassembly detection sensor 12B is a sensor that detects when the pressurizing cylinder 1 and the pressurizing lid 2 have been disassembled. When the pressurizing cylinder 1 and the pressurizing lid 2 have been disassembled, the disassembly detection sensor 12B outputs a disassembly detection signal to the pre-replacement timing prediction device 100. Furthermore, the kneader 10 can be disassembled not only from the motor 9 side, but also from the reversing worm gear 8 and side plate 14B side. Therefore, a disassembly detection sensor 12C is provided to detect when the kneader 10 has been disassembled from the side of the reversing worm gear 8 and side plate 14B. When the kneader 10 is disassembled from the side of the reversing worm gear 8 and side plate 14B, the disassembly detection sensor 12C outputs a disassembly detection signal to the pre-replacement timing prediction device 100. The disassembly detection sensors 12A to 12C are, for example, contact type sensors.

[0013] Figure 2 is an electrical system block diagram of an example of a pre-replacement timing prediction device 100. The pre-replacement timing prediction device 100 is installed in the kneader 10. As shown in Figure 2, the pre-replacement timing prediction device 100 includes a computer 20. The computer 20 includes a CPU 32, RAM 34, NVM 36, and input / output (I / O ports) 38. The CPU 32, RAM 34, NVM 36, and input / output (I / O ports) 38 are connected to each other via a bus 40 so that they can communicate with one another.

[0014] RAM 34 is a memory that temporarily stores information and is used as work memory by the CPU 32. Examples of RAM 34 include DRAM (Dynamic Random Access Memory) or SRAM (Static Random Access Memory).

[0015] NVM36 is a non-volatile memory that stores various programs and parameters. An example of NVM36 is flash memory (e.g., EEPROM (Electrically Erasable and Programmable Read Only Memory)). NVM36 stores a replacement parts processing program 36P1 (see Figure 5) and a pre-replacement timing determination processing program 36P2 (see Figure 6). NVM36 also stores a password. NVM36 is provided with a storage area F, which is initially set to 1. NVM36 also stores pre-replacement timings K1, K2, and K3 (see also Figure 7) corresponding to each replacement part.

[0016] The functional section of the CPU 32 includes an input processing unit 32A, a determination unit 32B, a reading unit 32C, a set processing unit 32D, a capture unit 32E, and a display processing unit 32F. The CPU 32 reads a replacement parts replacement processing program 36P1 or a pre-replacement timing determination processing program 36P2 from the NVM 36, and executes the read replacement parts replacement processing program 36P1 or pre-replacement timing determination processing program 36P2 on the RAM 34 to perform replacement parts replacement processing or pre-replacement timing determination processing. The CPU 32 operates on the RAM 34 as an input processing unit 32A, a determination unit 32B, a reading unit 32C, a set processing unit 32D, an acquisition unit 32E, and a display processing unit 32F, in accordance with the replacement parts replacement process or the pre-replacement time determination process.

[0017] The input / output (I / O port) 38 is connected to the kneader 10, input device 22, display device 24, hour meters M1 to M5, and decomposition detection sensors 12A to 12C. The input device 22 consists of an operation panel and the like, and is equipped with various instruction buttons to input instructions.

[0018] Hour meters M1 to M5 are physical measuring devices that correspond to replacement parts 1 to 5 and accumulate the operating time of the corresponding replacement parts 1 to 5. Before the kneader 10 is shipped, hour meters M1 to M5 are set to measure the operating time of replacement parts 1 to 5. When the kneader 10 starts operating, an operation start signal is input to the computer 20, and when the kneader 10 stops operating, an operation stop signal is input to the computer 20. When the CPU 32 receives an operation start signal, it instructs hour meters M1 to M5 to measure the operating time, and when the CPU 32 receives an operation stop signal from the input device 22 according to the operation of an operator, it instructs hour meters M1 to M5 to stop measuring the operating time. Therefore, when the CPU 32 reads the measured values ​​from hour meters M1 to M5, it can find out the accumulated operating time of replacement parts 1 to 5.

[0019] Figure 3 shows an example of processing by the functional unit of the CPU 32.

[0020] The input processing unit 32A receives a specification from the input device 22 for one of the replacement parts 1 to 5, namely replacement part n (for example, replacement part 1). The determination unit 32B determines whether a password has been entered. If it is determined that a password has been entered, the reading unit 32C reads the password from the NVM 36. The determination unit 32B determines whether the entered password matches the read password. If it is determined that the entered password matches the read password, the set processing unit 32D sets 1 in the storage area F. The set processing unit 32D resets the hour meter Mn of replacement part n.

[0021] Figure 4 is another diagram showing an example of the processing performed by the CPU 32.

[0022] The input unit 32E receives signals from the disassembly detection sensors 12A to 12C. The determination unit 32B determines whether a disassembly detection signal is output from any of the disassembly detection sensors 12A to 12C, and for example, whether the side plate 14A has been disassembled from the mixing tank 6. If it is determined that the side plate 14 has been disassembled from the mixing tank 6, the read unit 32C reads the value of the memory area F of the NVM 36. If it is determined that the value of the memory area F is not 1, the display processing unit 32F displays on the display device 24 that it will not notify the time for replacement.

[0023] (Operation) Figure 5 is a flowchart of an example of a replacement parts replacement processing program executed by the CPU 32.

[0024] When an operator replaces any of the replacement parts 1 to 5, specifically replacement part n (for example, replacement part 1), they operate the replacement part replacement process start button on the input device 22. This starts the execution of the replacement part replacement process program 36P1. The CPU 32 executes the replacement part replacement process program 36P1, thereby executing the replacement part replacement process and the replacement part replacement process method.

[0025] When an operator replaces one of replacement parts 1 to 5 or 7, specifically replacement part n (for example, replacement part 1), they specify which replacement part n (for example, replacement part 1) to replace via the input device 22.

[0026] In step 52, the input processing unit 32A receives a designation from the input device 22 for one of the replacement parts 1 to 5, namely replacement part n (for example, replacement part 1).

[0027] In step 54, the determination unit 32B determines whether or not a password has been entered.

[0028] In this embodiment, if the worker replacing the replacement parts is a predetermined worker, it is assumed that they know the correct password and that they should enter that password.

[0029] If it is determined that a password has not been entered, it can be determined that the worker replacing the replacement part is not the predetermined worker, and the replacement part replacement process proceeds to step 66.

[0030] If it is determined that a password has been entered, this replacement parts replacement process proceeds to step 56.

[0031] In step 56, the reading unit 32C reads the password from the NVM 36.

[0032] In step 58, the determination unit 32B determines whether the entered password matches the read password.

[0033] If the entered password and the retrieved password are not determined to match, it can be determined that the worker replacing the replacement part is not the predetermined worker, and the replacement part replacement process proceeds to step 66.

[0034] If it is determined that the entered password matches the retrieved password, the worker who will replace the replacement part can be determined to be the predetermined worker, and the replacement part replacement process proceeds to step 60.

[0035] In step 60, the set processing unit 32D sets 1 in the memory area F.

[0036] For example, when the side plate 14A is disassembled from the mixing tank 6 in order to replace the replacement part n (see also Figure 8), even if the disassembly detection sensor 12A detects that the side plate 14A has been disassembled from the mixing tank 6, if 1 is set in the memory area F, it can be determined that the worker who disassembled the side plate 14 from the mixing tank 6 is a predetermined worker.

[0037] When the worker has finished replacing the part, they input the completion of the replacement of part n via the input device 22.

[0038] Therefore, in step 62, the input processing unit 32A receives input indicating that the replacement of replacement part n has been completed.

[0039] In step 64, the setting processing unit 32D resets and starts the hour meter Mn of the replacement part n. Therefore, the operation time of the newly replaced replacement part n is newly measured from 0 by the hour meter Mn of the replacement part n.

[0040] When step 54 or step 58 results in a negative determination, the operator who replaces the replacement part can determine that the operator is not the predetermined operator. Therefore, in step 66, the setting processing unit 32D sets 0 in the storage area F. When 0 is set in the storage area F, for example, it can be determined that the operator who disassembled the side plate 14A from the mixing tank 6 is not the predetermined operator.

[0041] When the processing of step 64 or step 66 ends, this replacement part replacement process ends.

[0042] FIG. 6 is a flowchart of an example of a pre-replacement timing arrival determination processing program 36P2 executed by the CPU 32.

[0043] The pre-replacement timing arrival determination processing program 36P2 starts when an operation start signal is input from the kneader 10. By the CPU 32 executing the pre-replacement timing arrival determination processing program 36P2, the pre-replacement timing arrival determination processing and the pre-replacement timing arrival determination processing are executed.

[0044] In step 82, the capture unit 32E captures signals from the disassembly detection sensors 12A to 12C.

[0045] As described above, for example, when the side plate 14A is disassembled from the mixing tank 6, a disassembly detection signal is output from the disassembly detection sensor 12A to the pre-replacement timing prediction device 100.

[0046] Therefore, in step 84, the determination unit 32B determines whether a disassembly detection signal is output from the disassembly detection sensors 12A to 12C, thereby determining whether, for example, the side plate 14 has been disassembled from the mixing tank 6 (see also FIG. 8). If it is determined that the side plate 14 has not been disassembled from the mixing tank 6, the pre-replacement timing arrival determination processing proceeds to step 90. If it is determined that the side plate 14 has been disassembled from the mixing tank 6, the pre-replacement timing arrival determination processing proceeds to step 86.

[0047] In step 86, the reading unit 32C reads the value of the storage area F of the NVM 36. In step 88, the determination unit 32B determines whether the value of the storage area F is 1.

[0048] When it is determined that the value of the storage area F is 1, it can be determined that the operator who replaced the replacement part is a predetermined operator, and the pre-replacement time arrival determination process proceeds to step 90.

[0049] In step 90, the reading unit 32C reads the operation integrated time Tn of the hour meter Mn of each replacement part n.

[0050] In step 92, the reading unit 32C reads the replacement time Kn of each replacement part n from the NVM 36.

[0051] FIG. 7 is a diagram showing the replacement times T1, T2, T3 of the replacement parts 1 to 3 and the pre-replacement times K1, K2, K3 a predetermined time (for example, 48 hours) before each replacement time. As shown in FIG. 7, the replacement times T1, T2, T3 of the replacement parts 1 to 3 are different from each other. Also, the reason for setting the pre-replacement times K1, K2, K3 to a predetermined time before the replacement times T1, T2, T3 is as follows. When the replacement parts 1 to 3 reach the replacement times T1, T2, T3, even if it is displayed that the replacement parts 1 to 3 have reached the replacement times T1, T2, T3, or even if the staff arranges for the operator to replace the replacement parts, it takes a certain amount of time until the operator actually comes to the kneader 10 and performs the work. In order to make it so that the time when the operator actually comes to the kneader 1 and performs the work is before the replacement times T1, T2, T3 of the replacement parts 1 to 3, the pre-replacement times K1, K2, K3 are determined.

[0052] In step 94, the determination unit 32B determines whether the operation integrated time Tn of the hour meter Mn of each replacement part n has passed the pre-replacement times K1, K2, K3 (Tn > Kn). The determination unit 32B in step 94 is an example of the "determination unit" of the technology of the present disclosure.

[0053] When it is determined that the operation integrated time Tn of the hour meter Mn of each replacement part n has passed the pre-replacement times K1, K2, K3, the pre-replacement time arrival determination process proceeds to step 96.

[0054] In step 96, the display processing unit 32F displays on the display device 24 that replacement equipment n should be replaced, that is, that the pre-replacement time has been reached. As described above, the pre-replacement times K1, K2, and K3 are set earlier than the replacement times T1, T2, and T3 of replacement parts 1 to 3. Therefore, when an employee sees the display, they can arrange for a worker to replace the replacement part, and the worker actually comes to the mixer 10 to perform the work, it can be done before the replacement times T1, T2, and T3 of replacement parts 1 to 3. The display device 24 in step 96 is an example of a "notification unit" in the technology of this disclosure. The notification unit is not limited to displaying on the display device 24, but may also, or in addition to this, leave an audible message or notify the employee's communication terminal by email.

[0055] In step 98, the determination unit 32B determines whether or not the operation of the kneader 10 has stopped by determining whether or not an operation stop signal has been output from the kneader 10.

[0056] If it is not determined that the mixing machine 10 has stopped operating, the pre-replacement timing determination process returns to step 90 and executes the above processes (steps 90 to 98).

[0057] If it is determined that the mixing machine 10 has stopped operating, the pre-replacement timing determination process is terminated.

[0058] If, in step 88, the value of memory area F is not determined to be 1, it can be determined that the worker who replaced the replacement part is not a predetermined worker, and the pre-replacement timing determination process proceeds to step 100.

[0059] In step 100, the display processing unit 32F displays on the display device 24 that the kneader 10 has been disassembled by an operator other than the predetermined operator and that it will not be notified that it is time for replacement. The display device 24 in step 100 is an example of a "display unit" of the technology of this disclosure.

[0060] After the processing in step 100, the pre-replacement timing determination process is completed. That is, if it is determined that the worker who replaced the replacement part is not a predetermined worker, the processing in steps 90 to 98 is not executed. Therefore, the fact that each replacement part has reached its replacement time is not displayed (i.e., notified).

[0061] (Effects) As described above, in this embodiment, the cumulative operating values ​​of the multiple hour meters M1 to M5 and M7 for each of the multiple replacement parts 1 to 5 and 7, and the predetermined pre-replacement times for each of the multiple replacement parts 1 to 5 and 7 of the kneader 10, are used to determine whether each of the multiple replacement parts 1 to 5 and 7 has reached its respective pre-replacement time. Therefore, it is possible to determine whether replacement parts other than specific replacement parts should be replaced.

[0062] In this embodiment, if any of the multiple replacement parts have reached their pre-replacement period, that is, if it is determined that the replacement part should be replaced, the replacement part will display a message indicating that it should be replaced. Therefore, it becomes possible to replace the replacement part before it breaks down, allowing the kneader to operate in optimal condition.

[0063] Incidentally, when an employee sees a sign indicating that replacement parts should be replaced, they request the replacement of the parts from a predetermined worker. However, it is also possible that the employee may request the replacement of the parts from a worker other than the predetermined worker. Specifically, it is possible that the employee may request the replacement from a manufacturer that sells, repairs, or replaces parts compatible with the replacement parts of the kneader (a so-called third party), rather than the original manufacturer of the kneader. The worker other than the predetermined worker disassembles the kneader 10 to replace the parts without entering the password or without entering the correct password.

[0064] In this manner, if the kneader 10 is disassembled, especially if it is disassembled by an operator other than the designated operator, this embodiment does not display a notification even if the replacement parts have reached their replacement time. If the operator is not notified that the replacement parts have reached their replacement time, the replacement parts may be damaged, making it impossible to operate the kneader in optimal condition. In such a situation, the operator will request the designated operator to replace the replacement parts to prevent this from happening. This embodiment can passively encourage the operator to request the designated operator to replace the replacement parts.

[0065] In this embodiment, the display device 24 indicates that the kneader 10 has been disassembled by a worker other than the designated worker, and that the replacement time has not been notified. Therefore, even when each replacement part reaches its pre-replacement time, this is not displayed. As a result, the staff will request the replacement of the parts from the designated worker in order to operate the kneader in an optimal state. Thus, this embodiment can actively encourage the staff to request the replacement of parts from the designated worker.

[0066] As described above, an employee who is passively or actively instructed to request the replacement of parts from a predetermined worker will request the replacement of parts from the predetermined worker. Therefore, this embodiment makes it possible to correctly replace parts and operate the kneader in an optimal state. Furthermore, it reduces the risk of improper maintenance by an employee who is not a predetermined worker. Moreover, since a predetermined worker will replace each part in the appropriate procedure, the safety of the kneader 10 can be ensured, and accidents due to errors during replacement work by an employee who is not a predetermined worker can be prevented.

[0067] Furthermore, this embodiment ensures that the kneader operates under optimal conditions.

[0068] Furthermore, a company employing workers other than those predetermined may conduct business under a license from the original manufacturer of the predetermined worker, in which case the original manufacturer can earn a license fee.

[0069] In the above embodiment, a physical measuring device (hour meter) is used to accumulate the operating time of replacement parts. Since the physical measuring device (hour meter) starts measuring operating time simply by attaching it to the kneader 10, no setting or programming is required, and the introduction of the physical measuring device (hour meter) is easy.

[0070] [Variations] Various modifications are described below. Since each modification is substantially the same as the above embodiment, only the differences will be explained.

[0071] (First Modification) In the above embodiment, the NVM 36 stores in advance pre-replacement times K1, K2, K3 (see also Figure 7) corresponding to each replacement part. The technology of this disclosure is not limited thereto. For example, it may include a plurality of pre-replacement time arrival determination units that predict the pre-replacement time for each of the plurality of replacement parts. Then, it may be determined whether each of the plurality of replacement parts 1 to 5 has reached its respective pre-replacement time based on the accumulated operating values ​​of the plurality of hour meters M1 to M5 for each of the plurality of replacement parts 1 to 5 and the predicted pre-replacement time for each of the plurality of replacement parts 1 to 5 of the kneader 10.

[0072] The pre-replacement timing determination unit may directly predict each pre-replacement timing, or it may predict replacement timings T1, T2, T3... and then predict each pre-replacement timing by subtracting a predetermined time from the predicted replacement timings T1, T2, T3...

[0073] The replacement timings T1, T2, T3... may be predicted, for example, firstly, using artificial intelligence (AI), or secondly, by calculating the degradation trend of each replacement part from the output of sensors such as temperature sensors or vibration sensors, and then predicting the replacement timings T1, T2, T3... from the calculated degradation trend.

[0074] In the first modified example, the cumulative operating values ​​of multiple hour meters M1 to M5 for each of the multiple replacement parts 1 to 5, and the predicted pre-replacement time for each of the multiple replacement parts 1 to 5 of the kneader 10, are used to determine whether each of the multiple replacement parts 1 to 5 has reached its respective pre-replacement time. This makes it possible to determine whether replacement parts other than a specific replacement part should be replaced.

[0075] The first modified example includes multiple pre-replacement timing determination units that predict the pre-replacement timing for each of the multiple replacement parts. Therefore, even if the pre-replacement timing for replacement parts is not predetermined, it is possible to determine whether replacement parts other than a specific replacement part should be replaced.

[0076] (Second variation) The second variation is almost identical to the first variation, so I will explain the differences.

[0077] In the first modified example, if step 88 (see Figure 6) is determined to be negative, the processes in steps 90 to 98 are not executed. In other words, it is not determined whether each replacement part has reached its pre-replacement time. The technology of this disclosure is not limited thereto. For example, if step 88 (see Figure 6) is determined to be negative, the multiple pre-replacement time determination units either firstly not predict the pre-replacement time for each of the multiple replacement parts (stop predicting the pre-replacement time), or secondly predict the pre-replacement time for each of the multiple replacement parts as an infinite amount of time (decreased prediction of the pre-replacement time). As a result, step 94 is always determined to be negative, the process in step 96 is not executed, and no indication (i.e., notification) that replacement part n should be replaced is made.

[0078] If the staff are not notified that a replacement part has reached the end of its lifespan, the replacement part may break, making it impossible to operate the mixer in optimal condition. In such a situation, the staff will be instructed to request the replacement of the part from a predetermined worker to prevent this from happening. The second modification allows the staff to proactively request the replacement of the part from a predetermined worker.

[0079] (Third Modification) In the above embodiment, if step 88 (see Figure 6) is determined to be negative, the processes in steps 90 to 98 are not executed. In other words, no indication (step 96) is made that the replacement part n should be replaced. The technology of the present disclosure may, in lieu of or in conjunction with this, be processed as follows: If step 88 (see Figure 6) is determined to be negative, the processes in steps 90 to 98 are executed, and if step 94 is determined to be positive, a notification that the replacement part n should be replaced is transmitted (notified) to a management device that manages a predetermined worker who will replace the replacement part.

[0080] In the third modification, an employee who is unaware that a replacement part has reached its pre-replacement date can be notified of this by a predetermined worker who is responsible for replacing the part. Therefore, in the third modification, a predetermined worker can receive requests from employees to replace the parts.

[0081] (Fourth Modification) In the above embodiment and the first to third modifications, a physical measuring device (hour meter) is used to accumulate the operating time of the replacement parts. However, the technology of this disclosure is not limited thereto, and the operating time of each of the replacement parts 1 to 5 may be accumulated by software. Since no physical device is used, the pre-replacement timing prediction device can be made simpler in configuration.

[0082] (Fifth variation) If a worker other than the predetermined worker replaces a replacement part, the mixer may either not operate the replaced part or limit the function of the replacement part. For example, the rotation speed of replacement part 3 (blade shaft) may be set to a speed lower than the predetermined rotation speed, for example, to 0 or 1 / 10 of the speed. This prevents the mixer from performing its original mixing function, prompting the predetermined worker to consult with the operator or request steel pipes.

[0083] (Sixth Modification) In the above embodiment, a kneader 10 was described as an example of a material mixing apparatus. However, the technology of this disclosure is not limited to a kneader 10 as a material mixing apparatus, and may also be an extruder 100 that automatically supplies the material mixed by the kneader 10 to the next process. Figure 9 is a schematic side view of an example of an extruder 100. As shown in Figure 9, the extruder 100 is equipped with a plurality of interchangeable parts. For example, interchangeable parts include gears, screws, etc. Gears or screws are replaced when they wear out. To replace the gears or screws, the upper case 102 and the lower case 104 are separated. A disassembly detection sensor 120 that detects when the upper case 102 and the lower case 104 are separated is located in the crack 106 between the upper case 102 and the lower case 104. The disassembly detection sensor 120 outputs a disassembly detection signal to the pre-replacement timing prediction device 100 (see also Figure 2) when the upper case 102 and the lower case 104 are separated. Even in the sixth modified example of the extruder 100, it is possible to determine whether replacement parts other than specific replacement parts should be replaced.

[0084] [Addendum] Based on the above disclosure, the following addendum is proposed.

[0085] (Note 1) A pre-replacement timing prediction device for a kneading material processing apparatus equipped with a plurality of replacement parts, which processes kneading material using the plurality of replacement parts, wherein the device determines when the pre-replacement timing for the replacement parts has arrived, and the device comprises a determination unit that determines whether each of the plurality of replacement parts has reached its respective pre-replacement timing.

[0086] (Note 2) The pre-replacement timing prediction device according to Note 1, comprising: a notification unit that notifies that the replacement part has reached the predicted pre-replacement timing; and a disassembly detection sensor that detects that the kneading material processing device has been disassembled, wherein the notification is not made when the disassembly detection sensor detects that the kneading material processing device has been disassembled.

[0087] (Note 3) The pre-replacement timing prediction device according to Note 2, further comprising a pre-replacement timing prediction unit that predicts the pre-replacement timing of each of the plurality of replacement parts, wherein when the disassembly detection sensor detects that the kneading material processing device has been disassembled, the pre-replacement timing prediction unit reduces or stops the prediction of the pre-replacement timing of the replacement parts so that the notification is not made.

[0088] (Note 4) The pre-replacement timing prediction device according to Note 2 or Note 3, further comprising a determination unit that determines whether the kneading material processing device has been disassembled by a third party, wherein the notification is not made when the determination unit determines that the kneading material processing device has been disassembled by a third party.

[0089] (Note 5) The determination unit uses the accumulated operating time calculated by an hour meter that accumulates the operating time of the replacement parts, and is a pre-replacement timing prediction device according to any one of Notes 1 to 5.

[0090] (Note 6) The pre-replacement timing prediction device according to any one of Notes 2 to 5, further comprising a display unit that indicates that the mixing material processing device has been detected to have been disassembled by the disassembly detection sensor.

[0091] (Note 7) A kneading material processing apparatus equipped with a pre-replacement timing prediction device as described in any one of Notes 1 to 6.

[0092] 10 Mixer 1-6 Replacement parts 1 Pressure cylinder 2 Pressure lid 3 Blade shaft 4 Blade 5 Bearing 6 Mixing tank 7 Supporter 14 Side plate 12A-12C Disassembly detection sensor 100 Pre-replacement timing prediction device 20 Computer 32 CPU 34 RAM 36 NVM 36P1 Replacement parts replacement processing program 36P2 Pre-replacement timing arrival determination processing program F Memory area 32A Input processing unit 32B Judgment unit 32C Read unit 32D Set processing unit 32E Take-up unit 32F Display processing unit 22 Input device 24 Display device M1-M Hour meter 100 Extruder 102 Upper case 104 Lower case 120 Disassembly detection sensor 106 Crack

Claims

1. A pre-replacement timing prediction device for a kneading material processing apparatus equipped with multiple replacement parts, which processes kneading material using the multiple replacement parts, the device comprising a determination unit that determines whether each of the multiple replacement parts has reached its respective pre-replacement timing.

2. The pre-replacement timing prediction device according to claim 1, comprising: a notification unit that notifies that the replacement part has reached the predicted pre-replacement time; and a disassembly detection sensor that detects that the kneading material processing device has been disassembled, wherein the notification is not made when the disassembly detection sensor detects that the kneading material processing device has been disassembled.

3. The pre-replacement timing prediction device according to claim 2, further comprising a pre-replacement timing prediction unit that predicts the pre-replacement timing of each of the plurality of replacement parts, wherein when the disassembly detection sensor detects that the kneading material processing device has been disassembled, the pre-replacement timing prediction unit reduces or stops the prediction of the pre-replacement timing of the replacement parts so that the notification is not made.

4. The pre-replacement timing prediction device according to claim 2, further comprising a determination unit for determining whether the kneading material processing device has been disassembled by a third party, wherein the notification is not made when the determination unit determines that the kneading material processing device has been disassembled by a third party.

5. The determination unit uses the accumulated operating time calculated by an hour meter that accumulates the operating time of the replacement part, as described in claim 1, for the pre-replacement timing prediction device.

6. The pre-replacement timing prediction device according to claim 2, further comprising a display unit that indicates that the mixing material processing device has been detected to have been disassembled by the disassembly detection sensor.

7. A kneading material processing apparatus equipped with a pre-replacement timing prediction device as described in claim 1.

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