Failure Classifying Device for Machine Mechanism Units
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Solution Overview
Problem
Conventional methods fail to detect and specify failure locations in machines when a controller does not generate an alarm, making it difficult and time-consuming to track down the cause of failures in complex mechanism units.
Innovation Solution
A failure classifying device and method that acquire and correlate data sets of failure units with constituent parts, extract feature keywords from failure events, and retrieve information to identify failure units even without alarm generation, using a computer-based system with a failure history database and feature extraction techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a controller detects errors or problems to generate alarm information, then failure tracking becomes easier and more efficient, but some failures cannot be detected and alarms are not generated, leading to increased time required to track down failures
Solution Approach 1:
The patent introduces an intermediary system (failure classifying device) that mediates between the controller's alarm system and the failure analysis process. This device collects both alarm information and non-alarm failure information, classifies them systematically, and provides a unified failure tracking mechanism that handles both detected and undetected failures.
Solution Approach 2:
The patent segments failure information into different categories (alarm-based and non-alarm-based failures) and processes them through different pathways. By dividing the failure tracking system into multiple classification channels, it can handle various types of failures appropriately without requiring a single detection mechanism.
2Loss of information
If keyword-based retrieval is used to search past failure reports, then information can be acquired from historical data, but it is difficult to specify failure locations from many portions of the mechanism unit
Solution Approach 1:
The patent replaces manual keyword-based search and analysis with an automated information processing system. The failure classifying device uses computer-based classification algorithms to automatically analyze failure information, extract relevant features, and identify specific failure locations, substituting human cognitive processing with automated computational methods.
Solution Approach 2:
The patent transforms unstructured failure description text into structured classification data by extracting key parameters and features. This parameter transformation enables precise failure location identification by converting qualitative descriptions into quantifiable classification categories that can be systematically analyzed.
3Adaptability or versatility
If many constituent parts are present in a mechanism unit, then the machine becomes more functional and versatile, but the time required to track down failures increases considerably
Solution Approach 1:
The patent segments the complex mechanism unit into multiple failure units, each with specific constituent parts. By dividing the overall system into manageable segments, the failure classification process can focus on specific portions rather than analyzing the entire complex system, significantly reducing diagnosis time.
Solution Approach 2:
The patent performs preliminary classification and organization of constituent parts into failure units before failures occur. This pre-structuring of information allows for rapid failure diagnosis when problems arise, as the classification framework is already in place to guide the analysis process.
Data Source
AI summary
Provided are a failure classifying device, a failure classifying method, and a failure classifying program capable of specifying the causes of failures even when a controller does not generate an alarm. A failure classifying device includes: a failure unit acquiring unit that acquires a data set in which a failure unit of a machine is correlated with one or a plurality of constituent parts; a failure history acquiring unit that acquires a failure history including events of failures that occurred in the past and countermeasure parts; and a correlating unit that stores information on one or a plurality of events in correlation with the failure unit by matching the constituent part to the countermeasure part.