Failure Diagnosis Unit for Real-Time Error Cause Identification
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Solution Overview
Problem
Existing equipment diagnosis devices cannot identify the cause of errors in real-time, requiring systems to stop operations when errors are detected, making them unsuitable for continuous operation during fault conditions.
Innovation Solution
A control device with an error detection unit and a failure diagnosis unit that calculates a diagnosable time to identify the cause of errors based on posterior probabilities, allowing systems to continue operating by switching to fallback modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the equipment diagnosis device uses the Bayesian method to calculate posterior probability for identifying error causes, then the diagnosis accuracy is improved, but the diagnosis time increases and the system must be stopped
Solution Approach 1:
The patent pre-calculates and stores the posterior probability values for various phenomena causing errors before actual operation. When an error occurs, the diagnosis device directly retrieves these pre-computed values from storage rather than performing Bayesian calculations in real-time, significantly reducing diagnosis time while maintaining accurate identification of error causes
Solution Approach 2:
The patent dynamically adjusts the diagnosis process by setting a predetermined time threshold. If the initial diagnosis using pre-stored probabilities does not identify the error cause within the allowed time, the system automatically extends the diagnosis period or switches to alternative diagnosis methods, allowing flexible adaptation to time constraints while pursuing accurate diagnosis
2Measurement precision
If the system stops operations to conduct thorough error diagnosis, then the diagnosis accuracy is improved, but the productivity decreases
Solution Approach 1:
By pre-calculating and storing posterior probabilities for various failure scenarios, the system enables rapid error cause identification without interrupting operations. The pre-stored data allows the diagnosis to be performed in real-time during system operation, maintaining both high diagnostic accuracy and continuous productivity
Solution Approach 2:
The patent enables the diagnosis process to run concurrently with system operations by using pre-computed probability data. The error detection and diagnosis functions operate continuously without requiring system shutdown, allowing the useful action of both diagnosis and production to proceed simultaneously
Data Source
AI summary
A control device including a failure diagnosis unit configured to identify a phenomenon that is a cause of the detected error, wherein the failure diagnosis unit is configured to: calculate a diagnosable time available to be spent on the identification of the phenomenon that is the cause of the error; and identify, for each detected error, a phenomenon that is the cause of the error based on a posterior probability, which is calculated for each phenomenon that is likely to be the cause of the error as a probability of occurrence of the phenomenon, on a diagnosis time, which is obtained for each phenomenon as a period of time required to identify the phenomenon as the cause of the error, and on the diagnosable time.