Production Machine Fault Detection After Long Idle Periods
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Solution Overview
Problem
Existing malfunction detection methods in production machines, such as those with motors, often result in false positives when the machine has been idle for a long period, leading to unnecessary maintenance due to increased viscosity of lubricating oils and other operational conditions unrelated to motor performance.
Innovation Solution
A malfunction determination method and device that assesses the operation history of a production machine to identify prolonged stop periods, setting a suspension period for malfunction detection to prevent false alarms, using sensor data like torque and vibration values, and determining malfunctions only outside this period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If malfunction determination is performed continuously based on motor operational conditions, then detection precision is improved, but false detection increases when the production machine has been idle for a long period
Solution Approach 1:
The system performs preliminary determination of the operation stop period before conducting malfunction determination. By checking operation history in advance and identifying prolonged idle periods, the system prepares to suspend malfunction determination during these periods, thereby preventing false detections while maintaining detection precision during normal operation.
Solution Approach 2:
The malfunction determination system dynamically adjusts its operation based on the detected operation stop period. When a prolonged stop period is detected, the system suspends malfunction determination; when normal operation is detected, the system performs malfunction determination. This dynamic adjustment resolves the contradiction between continuous detection precision and avoidance of false positives during idle periods.
2Reliability
If malfunction determination is suspended after prolonged idle period, then false detection is reduced, but detection time increases due to additional operation history analysis
Solution Approach 1:
The operation stop period determination is performed preliminarily and continuously in the background using operation history data. This preliminary analysis is already available when malfunction determination is needed, so no additional time is required at the moment of malfunction checking. The system efficiently retrieves pre-analyzed operation stop period information to make quick decisions about suspending or performing malfunction determination.
3Productivity
If malfunction determination is performed without considering operation stop period, then productivity is maintained through continuous monitoring, but false alarms increase leading to unnecessary maintenance
Solution Approach 1:
The system applies different determination qualities to different operational contexts. During normal operation periods, full malfunction determination is performed with complete analysis. During prolonged operation stop periods, malfunction determination is suspended entirely. This localized adjustment of determination behavior based on operational context maintains productivity through continuous monitoring while eliminating false alarms during idle periods.
Data Source
AI summary
A malfunction determination method for a production machine including a motor as a driving source of a rotating mechanism acquires sensor data of a sensor for detecting a condition of the production machine, determines whether the production machine has an operation stop period during which the production machine has stopped its operation for a predetermined period of time or longer in accordance with an operation history of the production machine, sets a malfunction determination suspension period for suspending a malfunction determination of the production machine when determined to have the operation stop period, in accordance with a length of the operation stop period, and determines whether the production machine has a malfunction in a period other than the malfunction determination suspension period.