Banknote Conveying Log Analysis for Early Abnormality Detection
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Solution Overview
Problem
Existing banknote conveying apparatuses face issues with maintainability due to the need for highly skilled technicians to analyze operation logs and identify abnormality factors, which is labor-intensive and difficult to improve.
Innovation Solution
A banknote conveying apparatus equipped with sensors, a conveyance controller, and a processor that generates logs, calculates abnormality tendency thresholds, and determines the presence of abnormalities based on conveying speeds, providing automated notification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a worker manually analyzes operation logs to identify abnormality factors, then the analysis can be performed with existing systems, but the work is very man-hour intensive and requires technicians with sufficient knowledge about the banknote conveying apparatus
Solution Approach 1:
The system performs self-diagnosis by automatically analyzing operation logs and detecting abnormality factors without requiring manual intervention from technicians. The abnormality detection unit autonomously processes log data, identifies patterns, and determines abnormal conditions, enabling the system to service itself and eliminate the need for labor-intensive manual analysis.
Solution Approach 2:
The patent replaces the mechanical manual analysis process with an automated information processing system. The processor automatically reads operation logs, calculates conveying speeds, compares them against threshold values, and identifies abnormalities, substituting human cognitive and analytical work with computational processes that are faster and more consistent.
2Reliability
If a worker manually analyzes operation logs to identify abnormality factors, then the system can detect abnormalities, but it requires a technician who sufficiently understands the control conditions of the banknote conveying apparatus and the mechanism of the apparatus
Solution Approach 1:
The system encapsulates complex control conditions and mechanical knowledge within the abnormality detection unit. The unit automatically interprets operation logs, understands conveying mechanisms through programmed logic, and identifies abnormalities without requiring external technicians to possess detailed knowledge of the apparatus control conditions and mechanics.
Solution Approach 2:
The abnormality detection unit serves as an intermediary between the operation logs and the final abnormality determination. It processes raw log data, applies complex detection rules internally, and outputs simplified abnormality conclusions, acting as a mediator that translates complex technical information into actionable results without requiring the user to understand the underlying complexity.
3Reliability
If the resin for the roller expands due to a change in environmental temperature, then the conveyance of the banknote becomes unstable, but this physical change is difficult to detect and analyze from operation logs
Solution Approach 1:
The patent replaces direct physical measurement of roller expansion with indirect detection through operation log analysis. The system monitors conveying speed variations, timing deviations, and positional discrepancies in the operation logs, which are caused by thermal expansion, and infers the underlying physical problem from these operational symptoms without requiring direct measurement of the roller itself.
Solution Approach 2:
The operation log serves as an intermediary that translates physical roller expansion into measurable operational parameters. Instead of directly measuring the roller's dimensional changes, the system uses the log data containing conveying speed, timing, and position information as intermediaries to indirectly detect and analyze the thermal expansion effect on conveyance stability.
Data Source
AI summary
A banknote conveying apparatus includes, a conveyance controller that performs a conveying process of sequentially conveying a plurality of banknotes on a conveyance path, a plurality of sensors that detect the conveyed banknotes, and a processor coupled to a memory and configured to, generate a log in which past operation information including a detection result by the sensor is recorded, calculate an abnormality tendency threshold of a conveying speed for conveying a banknote between the sensors based on detection results of the sensors for the plurality of conveyed banknotes included in the log, and calculate a first conveying speed of a specific banknote between the sensors based on the log and determine presence or absence of an abnormality sign in conveyance of the specific banknote between the sensors based on whether the first conveying speed is included in a range indicated by the abnormality tendency threshold.