Hydraulic Shovel Component Life Span Estimation
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Solution Overview
Problem
Existing methods for estimating the life spans of components in operating machines are inaccurate due to variations in usage modes and require complex criteria, leading to inconsistent maintenance schedules.
Innovation Solution
An operating machine with a storage unit and arithmetic and control unit that classifies usage modes based on operation history and calculates life spans for each mode, improving accuracy by estimating life spans specific to each usage condition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If statistical processing is carried out on operating machines subject to different use conditions, then life span estimation can be performed, but the accuracy varies depending on usage mode and the criteria become complicated
Solution Approach 1:
The patent segments the population of operating machines by classifying them into distinct usage modes based on operation history analysis. This segmentation allows for separate life span estimation for each usage mode, improving accuracy while avoiding the need for complex mixed-mode criteria. The arithmetic and control unit automatically performs this classification and selects appropriate estimation criteria.
Solution Approach 2:
The patent changes the parameter of estimation accuracy by adapting the life span estimation criteria to match the specific usage mode parameters. Instead of using a single complex criteria set for all machines, the system selects appropriate criteria based on the detected usage mode, thereby improving accuracy without requiring the end user to manage complex criteria.
2Ease of operation
If periodic maintenance is performed based on operating time, then maintenance scheduling is simple, but it does not account for variations in actual component wear due to different operating conditions
Solution Approach 1:
The operating machine performs self-diagnosis and self-assessment of component life span by automatically analyzing its own operation history and comparing it against appropriate criteria. The arithmetic and control unit calculates the operating time in each usage mode and estimates component life span without external intervention, enabling the machine to self-determine its maintenance needs based on actual wear conditions.
Solution Approach 2:
The system implements feedback by continuously monitoring operation history, classifying usage modes, and adjusting life span estimation accordingly. This feedback loop allows the maintenance scheduling to adapt to actual operating conditions, improving reliability while maintaining ease of operation through automated decision-making.
Data Source
AI summary
A hydraulic shovel includes: a storage unit which stores an operation history of a target component of the shovel targeted for life span estimation, a discrimination threshold value used for classifying usage of the target component into a plurality of usage modes based on the operation history, and a usage mode-specific estimated life span indicative of an estimated life span of the target component in each of the usage modes; and an arithmetic and control unit which calculates an operating time of the target component in each of the usage modes in accordance with the operation history and the discrimination threshold value, and estimates the life span of the target component based on the operating time calculated for each of the usage modes and on the usage mode-specific estimated life span.