Machine State Monitoring with Correctable Non-Operation Analysis
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Solution Overview
Problem
Current factory operation monitoring devices provide limited information, such as 'alarm stopped,' 'halt,' and 'operating,' which is not sufficient for a precise understanding of machine operation states, leading to inaccurate analysis and low accuracy in identifying non-operation reasons.
Innovation Solution
An operation monitoring device that classifies machine states into operating and non-operating states based on analytical data, allowing users to correct analysis results, providing detailed information for improved understanding and decision-making.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional factory operation monitoring devices are used to provide limited information (alarm stopped, halt, operating), then the device complexity is low, but the measurement precision of machine operation states is insufficient
Solution Approach 1:
The patent segments the machine operation states into multiple detailed categories including operating state, halt state, alarming state, and wait state, each with specific sub-categories. This segmentation allows precise identification of machine states while maintaining manageable system complexity through structured classification.
Solution Approach 2:
The patent introduces an operation monitoring device as an intermediary system that collects data from multiple machine components (control unit, sensors, logs) and processes this information to provide comprehensive state analysis. This intermediary approach enables precise measurement without requiring direct modification of the machine's core systems.
2Loss of information
If detailed information on machine states is provided, then the loss of information is reduced, but the device complexity increases
Solution Approach 1:
The patent segments operation losses into distinct categories (wait loss, halt loss, set-up loss) with specific sub-categories for each. This segmentation ensures comprehensive information capture while organizing data in a structured manner that prevents system complexity from becoming unmanageable.
Solution Approach 2:
The patent adds a temporal dimension to the information system by tracking the duration of each state and calculating time-based metrics. This dimensional approach provides comprehensive loss information without requiring complex real-time processing, as the system can analyze accumulated data over time periods.
3Loss of time
If automatic analysis of machine states is performed, then the loss of time for manual analysis is reduced, but the measurement precision of non-operation reasons decreases
Solution Approach 1:
The patent implements feedback mechanisms where the monitoring system automatically analyzes machine states and provides results, which can then be reviewed and corrected by operators. This feedback loop enables time-efficient automatic analysis while maintaining precision through human verification of automated determinations.
Solution Approach 2:
The system performs self-service automatic analysis of machine states using predefined criteria and algorithms to determine operation states and reasons for non-operation. This self-service capability reduces manual analysis time while maintaining acceptable precision through automated decision-making rules.
4Productivity
If comprehensive operation monitoring is implemented, then the productivity improvement potential increases, but the loss of time for data collection and processing increases
Solution Approach 1:
The patent implements preliminary data collection by continuously monitoring and storing machine state information in real-time during normal operation. This preliminary action ensures that comprehensive data is already available when analysis is needed, eliminating the need for time-consuming data collection during analysis periods and enabling rapid productivity assessments.
Data Source
AI summary
An operation monitoring device includes an analytical data obtaining unit for obtaining analytical data that contain history information of a machine; a non-operation reason analysis unit for analyzing the state of the machine by classifying the state of the machine for every predetermined time as either of an operating state and a plurality of kinds of non-operating states, based on the analytical data, the operating state being a state in which the machine is operating, and the non-operating states being classified based on a reason for non-operation; a storage unit for storing an analysis result storage database that stores the result of analysis; a display unit for presenting to a user the result of the analysis; and a correction unit for correcting the result of the analysis according to an instruction from the user.