Numerical Controller Write-Life Prediction for Storage Media
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Solution Overview
Problem
Conventional service life monitoring devices for SSDs in numerical controllers can only detect write errors at the time of occurrence, failing to predict future service life degradation, which may lead to unexpected reduction in storage medium lifespan due to increased load from shorter data logger intervals.
Innovation Solution
A numerical controller with an interval setting unit, reduced service life calculation unit, and signal output unit that calculates and alerts on potential service life reduction based on set time intervals, allowing for proactive replacement and preventing unintended service life reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the data logger interval is shortened to increase monitoring frequency, then the operational monitoring capability is improved, but the service life of the storage medium deteriorates due to increased write operations
Solution Approach 1:
The system performs preliminary calculation of reduced service life based on the set time interval before actual storage operations begin. The reduced service life calculation unit computes the expected service life reduction in advance, allowing operators to adjust monitoring intervals or replace storage media proactively before actual damage occurs, thus resolving the contradiction between monitoring frequency and storage medium longevity
Solution Approach 2:
The determining unit continuously monitors the calculated reduced service life and compares it against a threshold value. When the reduced service life exceeds the threshold, the signal output unit provides feedback to operators. This feedback mechanism enables dynamic adjustment of monitoring strategies to balance operational needs with storage medium preservation
2Device complexity
If conventional service life monitoring is used that only detects errors at occurrence, then the system complexity is kept low, but the reliability of storage medium management deteriorates due to inability to predict future failures
Solution Approach 1:
Instead of waiting for errors to occur, the system performs preliminary calculations of reduced service life based on configured time intervals. This predictive approach allows the system to anticipate potential storage medium failures before they happen, significantly improving reliability while maintaining relatively simple system architecture through straightforward calculation and threshold comparison logic
Data Source
AI summary
A numerical controller that collects data from an industrial machine and writes data into a storage medium includes: an interval setting unit that sets a time interval between cycles in which one cycle involves collection of operation information indicating an operating state of the industrial machine and writing of the collected operation information to the storage medium; a reduced service life calculation unit that calculates a service life of the number of writes of the storage medium reduced by the writing on the basis of the set time interval as a reduced service life; a determining unit that determines whether the calculated reduced service life exceeds a prescribed threshold; and a signal output unit that outputs a signal indicating that the reduced service life exceeds the prescribed threshold when it is determined that the reduced service life exceeds the prescribed threshold.