Maintenance Policy Determination for Complex Forming Devices
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Solution Overview
Problem
Complex forming devices pose challenges in determining maintenance policies due to their complex structure, varied functions, and large operation data sets, making it difficult to estimate performance and select appropriate maintenance strategies, thereby increasing maintenance costs.
Innovation Solution
A method and system that utilize sample data sets with maintenance policy labels, establish a working condition hierarchical identification model, classify data items, calculate distances using a shortest path algorithm, and determine a maintenance policy based on Euclidean distances to select a suitable maintenance policy for the complex forming device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex forming device is used to complete various forming requirements, then the manufacturing capability and flexibility are improved, but the device complexity and difficulty in determining maintenance policy increase
Solution Approach 1:
The patent segments the complex forming device into multiple functional modules (e.g., hydraulic system, electrical system, mechanical system), and further divides each module into working condition units. This hierarchical segmentation transforms the undifferentiated complex device into manageable components, enabling targeted monitoring and maintenance policy determination for each segment based on its specific characteristics and operation data patterns.
2Measurement precision
If comprehensive operation data is collected from the complex forming device, then the measurement completeness is improved, but the data processing complexity and difficulty in estimating performance increase
Solution Approach 1:
The patent segments comprehensive operation data into module-specific data sets corresponding to different functional modules and working condition units. Each data set is processed independently through classification and distance calculation, transforming the overwhelming comprehensive data into structured, manageable segments that can be analyzed systematically to estimate device performance accuracy.
Solution Approach 2:
The patent introduces a hierarchical dimension to organize operation data, transitioning from flat comprehensive data to a multi-level structure with functional modules as first-level divisions and working condition units as second-level divisions. This dimensional transformation enables systematic processing of large-scale data by operating on smaller hierarchical levels rather than handling all data simultaneously.
3Ease of operation
If traditional maintenance policies are applied to the complex forming device, then the maintenance simplicity is maintained, but the maintenance costs and downtime increase
Solution Approach 1:
The patent changes the parameter basis for maintenance decisions from fixed time intervals or simple usage thresholds to dynamic parameters including working condition classification results and distance metrics that reflect actual device performance degradation. This parameter transformation enables maintenance timing to be optimized based on real-time device state, improving maintenance efficiency and reducing unnecessary maintenance operations while maintaining simplicity through automated parameter calculation.
Data Source
AI summary
The present invention discloses a method and system for determining a maintenance policy of a complex forming device. The method and system include: establishing a performance judgement standard; obtaining actual operation data; and determining a performance stage of the complex forming device, and determining the maintenance policy of the complex forming device. The establishing a performance judgement standard includes allocating data located at different performance stages to corresponding working condition units; setting data located at a normal performance stage to normal reference data, and calculating, by using a shortest path algorithm, distances between operation data of different working condition units in different functional modules and the normal reference data, to obtain performance statuses of the different functional modules. In view of this, by using the method and system provided in the present invention, a suitable maintenance policy can be selected for the complex forming device, thereby reducing maintenance costs.