Excavator Diagnostic System with Snapshot Data Extraction

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Solution Overview

Problem

Existing diagnostic systems for construction machines, such as large-sized hydraulic excavators, are ineffective in detecting abnormalities before they occur, leading to prolonged suspension periods and reduced productivity.

Innovation Solution

A diagnostic information providing apparatus with detection, storage, and display means that allows operators to select snapshot items, acquire and display status variable data, and compare it with predetermined reference values to determine potential failures, enabling early detection and display of abnormal conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If operation data is acquired only after abnormality detection, then failure diagnosis can be performed, but the suspension period of the construction machine cannot be reduced sufficiently

Engineering Contradiction:

Improvefailure diagnosis capabilityVSAvoidsuspension period

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by continuously monitoring status variables and comparing them against reference ranges before actual failure occurs. The abnormality detection unit identifies potential issues in advance, and the snapshot storage unit preserves relevant operation data proactively, enabling faster response when failure actually occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts data acquisition based on operational conditions. When abnormalities are detected, the system transitions from normal operation to abnormality detection mode, automatically capturing and storing snapshot data. This dynamic response allows the system to balance continuous monitoring with selective data acquisition, reducing overall data processing burden while maintaining diagnostic capability.

Inventive Principle:

Principle #15Dynamics

2Productivity

If continuous operation is maintained to increase productivity, then output increases, but abnormalities may go undetected until critical failure

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidabnormality detection timing

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system implements continuous feedback loops where status variables are constantly monitored and compared against predetermined reference ranges. When deviations are detected, the feedback mechanism triggers abnormality detection and automatic snapshot storage, allowing operators to receive real-time information about machine health without interrupting continuous operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The diagnostic system operates autonomously by automatically detecting abnormalities, determining which snapshot items are relevant, and storing corresponding operation data without requiring continuous operator intervention. The system serves itself by managing its own diagnostic functions, freeing operators to focus on primary tasks while maintaining surveillance of machine health.

Inventive Principle:

Principle #25Self-service

3Loss of information

If comprehensive operation data is stored for all snapshot items, then complete diagnostic information is available, but data storage and processing complexity increases

Engineering Contradiction:

Improvediagnostic information completenessVSAvoiddata storage and processing

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The system extracts only the necessary subset of operation data based on detected abnormalities. When the abnormality detection unit identifies specific issues, the snapshot storage unit selectively captures only the relevant snapshot items associated with those abnormalities, rather than storing all possible operation data. This extraction approach maintains diagnostic completeness for actual problems while minimizing unnecessary data storage.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Different levels of data storage are applied based on local conditions. The system maintains reference ranges and detection criteria for all snapshot items, but only stores complete operation data for items locally identified as abnormal or potentially problematic. This localized quality approach ensures comprehensive diagnostics where needed while reducing overall data burden.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS7684917B2Diagnostic information providing apparatus for construction machine and diagnostic information display system for construction machine

Publication Date: 2010.03.23 HITACHI CONSTRUCTION MACHINERY CO LTD

AI summary

A diagnostic information display system for a construction machine includes a sensor for detecting status variables related to an operating state of a hydraulic excavator or ambient environment, and a controller which stores combinations between a plurality of snapshot items and one or more status variables related to each of the snapshot items in advance, acquires or extracts status variable data, which is regarded as being related based on the stored combinations, from corresponding detected signals of the sensor 40, etc. with respect to the snapshot item selected by a selection command from an operator, thereby displaying the status variable data on a display unit, and compares each of the status variables or a value computed based on a plurality of status variables with a predetermined reference value range. A failure of a corresponding part or the related status variable is displayed on the display unit.