Manufacturing Abnormality Detection Using Split Diagnosis Architecture
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Solution Overview
Problem
Existing abnormality detection systems for manufacturing devices, such as injection molding machines, face challenges in detecting and diagnosing issues without imposing excessive load on the control device, leading to delays in operation control processing.
Innovation Solution
An abnormality detection system comprising a control device, an abnormality detection apparatus, and a diagnostic apparatus that collaboratively detect and diagnose issues using sensor data and operating data, with the abnormality detection apparatus calculating statistics and determining abnormalities based on thresholds, and the diagnostic apparatus providing detailed diagnostic results to the control device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control device is configured to detect or diagnose an abnormality of the production device, then the abnormality detection capability is improved, but the operation control processing is delayed and the control device is overloaded
Solution Approach 1:
The system is segmented into three distinct functional modules: a control device for operation control, an abnormality detection apparatus for detecting abnormalities using sensors and statistical analysis, and a diagnostic apparatus for detailed condition diagnosis. This segmentation allows each component to specialize in its specific function, preventing the control device from being overloaded with detection and diagnosis tasks while maintaining comprehensive monitoring capabilities.
Solution Approach 2:
The abnormality detection apparatus acts as an intermediary between the control device and the diagnostic apparatus. It receives sensor data, performs initial statistical analysis to detect abnormalities, and then transmits relevant data to the diagnostic apparatus for further analysis. This intermediary role protects the control device from direct involvement in complex detection and diagnosis operations, ensuring timely operation control processing.
2Productivity
If a separate abnormality detection apparatus and diagnostic apparatus are provided, then the control device is not overloaded, but the system complexity increases
Solution Approach 1:
The abnormality detection apparatus performs multiple functions: it collects sensor data, calculates statistical values, detects abnormalities by comparing statistics against thresholds, and transmits data to both the control device and diagnostic apparatus. This multi-functionality consolidates several operations into a single apparatus, reducing the need for additional specialized components and simplifying the overall system structure while maintaining high operation control efficiency.
Solution Approach 2:
The system merges the data collection, statistical analysis, abnormality detection, and data transmission functions into a single abnormality detection apparatus. This consolidation reduces the number of separate components needed compared to having entirely separate systems for each function, thereby managing system complexity while preserving productivity benefits.
3Device complexity
If the control device performs all operations including abnormality detection and diagnosis, then the system structure is simple, but the operation control processing is delayed
Solution Approach 1:
The system segments operations into three parallel processing streams: operation control by the control device, abnormality detection by the detection apparatus, and condition diagnosis by the diagnostic apparatus. This segmentation enables simultaneous execution of control and monitoring tasks without interference, maintaining simple system structure while achieving fast operation control processing speed through parallelization.
Data Source
AI summary
An abnormality detection system includes an abnormality detection apparatus that detects an abnormality of a production device, a control device that performs operation control of the manufacturing device and transmits operating data, a sensor that detects a physical quantity related to operation or a product of the manufacturing device and outputs sensor value data, and a diagnostic apparatus. The abnormality detection apparatus determines a presence or an absence of an abnormality of the manufacturing device based on the operating data transmitted from the control device and the sensor value data output from the sensor and transmits the determination result to the control device. The abnormality detection apparatus further transmits the operating data and the sensor value data to the diagnostic apparatus. The diagnostic apparatus diagnoses the condition of the manufacturing device based on sensor value data accumulated in the past in the database and the received data and transmits the diagnostic result to the abnormality detection apparatus. The abnormality detection apparatus transmits the diagnostic result to the control device.