Machine Diagnostic Apparatus Autonomous Operation Mode Detection
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Solution Overview
Problem
Existing machine diagnostic apparatuses face difficulties in applying to existing machines with unknown control specifications, particularly when the manufacturer of the diagnostic apparatus is different from the control computer, making it challenging to acquire and utilize the operation mode data.
Innovation Solution
A machine diagnostic apparatus that includes a sensor data acquisition unit, an operation mode data creation unit, an operation mode specifying unit, and an abnormality diagnosis unit, which acquires and processes time-series measurement data to specify the operation mode and diagnose abnormalities based on pre-defined procedures, eliminating the need for direct communication with the control computer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operation mode data is acquired from the control computer, then the abnormality diagnosis can be performed based on operation mode, but it becomes difficult to apply to existing machines with unknown control specifications or different manufacturers
Solution Approach 1:
The machine diagnostic apparatus autonomously determines the operation mode by itself using sensor data from the machine, without requiring operation mode information from the control computer. The apparatus creates operation mode data by analyzing time-series sensor data characteristics and automatically specifies the current operation mode by comparing real-time sensor data against stored operation mode data, enabling the system to serve itself rather than relying on external control computer information.
Solution Approach 2:
Sensor data serves as an intermediary medium between the machine and the diagnostic apparatus. Instead of directly acquiring operation mode information from the control computer, the apparatus uses sensor data as an intermediate载体 to infer and determine the operation mode indirectly, bypassing the need for direct communication with the control computer and enabling compatibility with machines from different manufacturers.
2Loss of information
If signal lines or programs are added to the control computer to output operation mode, then operation mode information becomes available, but it becomes substantially difficult to implement when manufacturers differ
Solution Approach 1:
The patent replaces the mechanical/system-level approach of adding signal lines and programs to the control computer with a data processing approach using sensor data analysis. Instead of modifying the control computer's hardware or software architecture, the diagnostic apparatus processes existing sensor data to extract operation mode information, eliminating the need for physical modifications to the control system.
Solution Approach 2:
The apparatus creates copies of operation mode data by analyzing and storing characteristic patterns from sensor data for different operation modes. These copied operation mode patterns are then used for comparison and identification, allowing the system to replicate the functionality of having direct operation mode information without actually accessing the control computer's internal state.
3Device complexity
If operation mode is not considered in diagnosis, then the diagnostic procedure is simpler, but false reports or report failures occur
Solution Approach 1:
The apparatus performs preliminary action by pre-storing operation mode data with characteristic sensor data patterns for each operation mode before actual diagnosis. This preliminary preparation allows the system to quickly and accurately determine the current operation mode during diagnosis by simple comparison, making the operation mode consideration process efficient and not significantly increasing overall diagnostic complexity.
Data Source
AI summary
An operation mode specifying unit specifies an operation mode of a machine by comparing time-series data of an amplitude and a frequency of measurement data obtained from a sensor with definition data of the operation mode of the machine created in advance by an operation mode data creation unit. In addition, an abnormality diagnosis unit performs processing of cluster analysis for the measurement data obtained from the sensor or the like, and diagnoses abnormality of the machine according to diagnosis procedure information that is set in advance depending on the set operation mode and an abnormality mode of the machine.