Fluid Control Operation Analysis for Abnormality Prediction
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Solution Overview
Problem
Existing fluid control devices face challenges in detecting abnormalities, such as leakage, in a compact configuration with integrated multiple devices, where external abnormality detection mechanisms are impractical due to size constraints and risk of wiring issues, and current systems cannot predict failures before they occur.
Innovation Solution
A network-enabled operation analysis system for fluid control devices that includes an operation information acquisition mechanism, an abnormality determination unit, and a correlation analysis unit, allowing for remote detection and prediction of abnormalities through data mining and analysis of operational data, including pressure, temperature, and usage patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external abnormality detection mechanisms are attached to fluid control devices, then abnormality detection capability is improved, but device size increases and wiring complexity increases
Solution Approach 1:
The abnormality detection sensor is integrated inside the fluid control device, with the sensor housed within the device body. The sensor detects abnormalities internally and transmits signals through existing internal pathways, eliminating the need for external attachment mechanisms and reducing overall device complexity while maintaining detection capability
Solution Approach 2:
A signal transmission mechanism serves as an intermediary between the internal sensor and external monitoring systems. This intermediary transmits abnormality detection signals through the device housing without requiring external wiring connections, thereby reducing wiring complexity while maintaining reliable signal transmission
2Productivity
If fluid control devices are downsized and densely arranged, then productivity is improved, but abnormality detection becomes more difficult
Solution Approach 1:
Mechanical external detection mechanisms are replaced with integrated electronic sensors and wireless communication systems. The sensor detects abnormalities electronically within the compact device, and wireless transmission eliminates the need for external physical connections, enabling dense arrangement while maintaining detection capability
Solution Approach 2:
The fluid control device incorporates multiple functions including fluid control, abnormality detection, and wireless communication within a single integrated unit. This multi-functionality eliminates the need for separate external detection devices, allowing dense arrangement while maintaining comprehensive monitoring capability
3Volume of moving object
If exposure to outside is reduced for compact configuration, then device size is reduced, but abnormality detection accuracy deteriorates
Solution Approach 1:
The sensor is nested within the device housing, positioned to detect abnormalities in the flow path and internal components. This internal nesting maintains compact device size while ensuring the sensor remains in optimal position for accurate detection of fluid leakage and component failures
Data Source
AI summary
A cause of abnormality of a fluid control device and/or data with which abnormality can be predicted can be collected to be analyzed, and abnormality can be predicted based on a result of the analysis.A fluid control device 8 and a server 72 are configured to be able to communicate with each other through networks NW1 and 2. The fluid control device 8 includes an operation information acquisition mechanism that acquires a plurality of types of operation information about the fluid control device 8. The server 72 includes a determination processing unit 721 that determines whether the fluid control device 8 has an abnormality, an information collection unit 724 that collects the operation information and an abnormality determination result for the fluid control device 1, an information storage unit 725 that stores the operation information and the determination result collected, an information extraction unit 726 that refers to the information storage unit 725, and extracts, analysis target including same predetermined operation information and another of the operation information as well as information related to the determination result, selectively for each of a plurality of the fluid control devices 1, and a correlation analysis unit 727 that analyzes correlation between a predetermined operation of the fluid control device 8 and occurrence of abnormality through comparison using the information extracted.