Monitoring Device Abnormal Waveform Generation for False Alarm Reduction
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Solution Overview
Problem
Existing monitoring systems frequently report false abnormalities in production devices, leading to unnecessary maintenance and decreased production efficiency, as they fail to distinguish between temporary and potentially problematic changes in physical quantities indicative of device state.
Innovation Solution
A monitoring device that acquires and analyzes physical quantities such as electric power consumption over time, generating abnormal waveforms only after a predetermined period of abnormality is confirmed, allowing for more accurate prediction of future trouble and reducing excessive reporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If abnormality is reported immediately when physical quantity exceeds threshold, then reliability of abnormality detection is improved, but false alarms increase and information reliability deteriorates
Solution Approach 1:
The system performs preliminary accumulation of abnormal data points before triggering an alarm. When a physical quantity exceeds the threshold, the system does not immediately report abnormality but continues monitoring and accumulates evidence. Only after a predetermined number of abnormal data points are accumulated does the system generate an alarm, allowing temporary fluctuations to resolve themselves while still detecting genuine abnormalities.
2Reliability
If maintenance is carried out at regular intervals, then device reliability is improved, but production efficiency deteriorates due to downtime
Solution Approach 1:
The system changes the parameter of maintenance timing from fixed periodic intervals to condition-based timing. By monitoring physical quantities and accumulating abnormal data points, the system enables maintenance to be performed only when actually needed, rather than following a rigid schedule. This allows production to continue uninterrupted while maintaining device reliability through timely, condition-based intervention.
3Reliability
If components are replaced based on operating time, then device reliability is improved, but resource waste increases due to premature replacement
Solution Approach 1:
The system changes the replacement decision parameter from operating time to accumulated abnormal data points. Instead of replacing components after a fixed operating duration, the system continuously monitors physical quantities and only triggers replacement when a predetermined number of abnormal readings are accumulated, allowing components to be used until they actually fail rather than being replaced preventively.
Data Source
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AI summary
An object of the present invention is to provide a monitoring device which facilitates determination of prediction of trouble while preventing excessive reporting. A monitoring device (20) includes: a physical quantity acquisition section (201) for acquiring physical quantities indicative of a state of a device; an abnormality determination section (203) for determining, in accordance with whether or not the acquired physical quantities fall within a predetermined range, whether or not there is an abnormality; an abnormal waveform data generation section (204) for, in a case where the abnormality determination section (203) determines that there is an abnormality, generating abnormal waveform data indicative of a change over time in the physical quantities acquired during an abnormal waveform period containing at least a period from a point in time at which the abnormality determination section (203) determines that there is an abnormality to a point in time at which a predetermined accumulation time elapsed; and a reporting section (206) for causing a display section (207) to display an abnormal waveform indicated by the abnormal waveform data.