Tempering Device Fault Diagnosis for Fast Error Localization
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Solution Overview
Problem
Tempering devices in systems often experience errors due to poor ambient or component conditions, leading to production halts and high standstill costs, especially in areas where immediate service technician availability is limited, necessitating the need for rapid and precise error identification and localization without relying on stored replacement appliances.
Innovation Solution
A diagnosis method and device equipped with first and second sensors that measure the tempering device's state and ambient conditions, allowing for a decoupling process to isolate errors, using a diagnosis program to check components and sensors in a predetermined sequence, enabling rapid identification and localization of faults, and potentially avoiding the need for external service technicians or replacement appliances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tempering device is used in a system, then the system can maintain required temperatures for successful processes, but errors in the tempering device can halt the entire production process and lead to high standstill costs
Solution Approach 1:
The diagnosis program performs preliminary checks of components and sensors in a predetermined sequence to identify and localize errors before they cause complete system failure. By proactively detecting faults through systematic diagnosis, the system can address issues early, preventing production halts and reducing standstill costs.
2Reliability
If replacement appliances are kept in storage to maintain availability, then production can continue without interruption, but additional financial cost is incurred due to the presence of replacement appliances
Solution Approach 1:
The tempering device performs self-diagnosis through the diagnosis program that automatically checks its own components and sensors. This self-monitoring capability allows the device to identify and report errors without external intervention, eliminating the need to maintain expensive replacement appliances in storage while ensuring production continuity through rapid fault detection and response.
3Loss of time
If service technicians are deployed immediately to address errors, then errors can be rectified quickly, but this is not feasible in areas where service technicians are not immediately available
Solution Approach 1:
The diagnosis program acts as an intermediary between the tempering device and service technicians. It performs preliminary error identification and localization, providing detailed diagnostic information that enables service technicians to arrive prepared with the correct solutions. This intermediary diagnostic system bridges the gap in areas where immediate technician availability is limited, reducing both response time and travel time.
4Measurement precision
If multiple sensors are added to increase measurement density for faster error source identification, then error localization becomes more precise, but device complexity increases
Solution Approach 1:
The diagnosis program segments the error detection process into specific check sequences for different components and sensors. By organizing the diagnosis into predetermined sequences that systematically evaluate each component, the system achieves precise error localization without requiring an excessive number of sensors. The segmented approach allows efficient use of existing sensors through structured diagnostic routines.
Data Source
AI summary
A diagnosis method for identification or localization of errors in tempering devices for tempering of systems includes providing tempering devices each comprising one or more first sensors and one or more components for securing an operation of the systems with the tempering device, and one or more second sensors for measuring a state of the tempering device or ambient conditions around the tempering device, determining the tempering device to be checked with a diagnosis procedure, decoupling the tempering device from the system, connecting the tempering device to a defined consumer, and conducting the diagnosis procedure for the tempering device by using a diagnosis program, where the diagnosis program checks the components and the first and second sensors of the tempering device in a pre-determined sequence stored in the diagnosis program until the error in the tempering device is identified or localized.