Press Slide Abnormality Diagnosis Without No-Load Interruption
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Solution Overview
Problem
Existing press machine diagnostic methods require a no-load condition for abnormality diagnosis, which increases user workload and is challenging due to disturbances from processing loads, making it difficult to accurately diagnose issues like seized sliding parts or frame cracks without interrupting production.
Innovation Solution
A press machine with a press control unit and an abnormality diagnostic unit that performs diagnosis based on sensor data while the slide moves at a predetermined speed between the bottom dead point and top dead point in a press-no-load state, eliminating the need for a user workload and reducing disturbance influence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If abnormality diagnosis is performed under no-load condition during production, then diagnostic accuracy is improved, but user workload increases and production is interrupted
Solution Approach 1:
The press machine performs abnormality diagnosis automatically using its own operational data without requiring external intervention or special no-load conditions. The system self-diagnoses by analyzing vibration patterns during normal production operations, eliminating the need for users to manually create no-load conditions or interrupt production for diagnosis.
Solution Approach 2:
The system continuously collects and analyzes vibration data during normal operations, preparing diagnostic information in advance rather than waiting for scheduled no-load diagnosis sessions. This allows the system to be ready to identify abnormalities before they lead to failures, without requiring production interruptions.
2Measurement precision
If abnormality diagnosis is performed under no-load condition during production, then diagnostic accuracy is improved, but production efficiency decreases
Solution Approach 1:
The diagnostic system operates continuously during normal production without requiring the press to be stopped or placed in no-load condition. Vibration sensors continuously monitor the press machine while it operates under various load conditions, maintaining both production continuity and diagnostic capability.
Solution Approach 2:
The system performs diagnostic analysis in real-time during production operations, preparing abnormality detection information as production proceeds rather than requiring separate diagnosis sessions that would interrupt production flow.
3Productivity
If vibration measurement is performed during production with processing load, then production continues without interruption, but measurement accuracy deteriorates due to large disturbance
Solution Approach 1:
The system changes the approach from requiring specific operational conditions (no-load) to analyzing vibration patterns across various operational parameters including different load conditions. By collecting vibration data under diverse operating conditions and using machine learning to distinguish normal operational vibrations from abnormality indicators, the system maintains measurement accuracy without requiring production interruptions.
Solution Approach 2:
The system uses feedback from continuous vibration monitoring during production to identify patterns that indicate abnormalities. By comparing real-time vibration data against learned normal patterns from various operational conditions, the system can detect abnormalities even during loaded production operations without sacrificing measurement accuracy.
Data Source
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AI summary
A press machine includes: a press control unit that controls ascending/descending motion of the slide; and an abnormality diagnostic unit configured to perform abnormality diagnosis of the press machine based on data from a sensor provided in the press machine and to output a result of the abnormality diagnosis. The abnormality diagnostic unit is configured to perform the abnormality diagnosis, based on the data acquired from the sensor while the slide moves at a predetermined speed between a bottom dead point and a top dead point in a press-no-load state.