Production Machine Fault Detection After Long Idle Periods
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Solution Overview
Problem
Existing malfunction detection methods in production machines, such as production robots, 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 oil and unrelated motor operational conditions.
Innovation Solution
A malfunction determination method and device that sets a suspension period for malfunction detection based on the length of the machine's operation stop time, preventing false alarms by suspending malfunction determination until the machine has been operational again, and using sensor data like disturbance torque and vibration values to assess actual malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If malfunction detection is continuously performed regardless of machine operational status, then malfunction detection coverage is improved, but false detection rate increases when machine is idle
Solution Approach 1:
The malfunction determination device dynamically adjusts its detection behavior based on the operational status of the production machine. When the machine is in a stopped state, the device suspends malfunction determination; when the machine is operating, the device performs normal malfunction detection. This dynamic adaptation resolves the contradiction by making the detection system flexible rather than static, thereby maintaining high detection coverage during operation while avoiding false positives during idle periods.
Solution Approach 2:
The system changes the operational parameter of malfunction determination based on the machine's operational state. The determination process is suspended during stopped states and activated during operating states. This parameter change approach allows the system to maintain reliable detection coverage when needed while preventing false detections when the machine is idle, thus resolving the technical contradiction between detection coverage and false detection rate.
2Measurement precision
If malfunction detection is suspended when machine is stopped, then false detection is reduced, but detection responsiveness worsens after long idle periods
Solution Approach 1:
The malfunction determination device performs preliminary assessment of the operational status before conducting malfunction determination. By checking whether the production machine is in an operating or stopped state beforehand, the system can appropriately suspend or continue detection. This preliminary action ensures that detection responsiveness is maintained when the machine is operational while preventing false detections during idle periods, thus resolving the contradiction between precision and responsiveness.
3Measurement precision
If malfunction determination considers operational history, then detection accuracy is improved, but system complexity increases
Solution Approach 1:
The malfunction determination device incorporates feedback from the operational status of the production machine into its determination process. By continuously monitoring whether the machine is operating or stopped and using this information to adjust detection behavior, the system improves detection accuracy without requiring complex additional hardware. The feedback mechanism simply suspends determination during stopped states and resumes during operating states, achieving high accuracy while maintaining relatively simple system architecture.
Data Source
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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.