Winding Body Inspection Notification for Predictive Maintenance
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Solution Overview
Problem
Current maintenance systems in production facilities often require stopping operations after an abnormality occurs, necessitating a method to detect signs of abnormalities before they lead to failures.
Innovation Solution
An information processing method and apparatus that utilize sensors to detect deviations in electrode sheet positions on a winding apparatus, generating learned models to predict and notify of potential issues, allowing for proactive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If maintenance is performed only after abnormality occurrence, then operational simplicity is maintained, but production downtime increases and reliability decreases
Solution Approach 1:
The system performs preliminary detection of abnormality signs before actual failures occur. The sensor detects positional deviations of electrode sheets and the notification device alerts operators to potential issues, enabling maintenance to be scheduled before critical failures happen, thus reducing production downtime while maintaining reliability
Solution Approach 2:
The system establishes a feedback loop where sensor data about electrode sheet positions is continuously monitored, analyzed for abnormality signs, and fed back to operators through notifications. This feedback mechanism enables proactive maintenance decisions based on actual facility state, improving reliability without unnecessary downtime
2Reliability
If continuous monitoring is implemented to detect abnormality signs early, then reliability improves, but device complexity and measurement difficulty increase
Solution Approach 1:
The system extracts only the critical measurement needed for early abnormality detection - the positional deviation of electrode sheet ends from their reference positions. By focusing on this specific parameter rather than comprehensive monitoring, the system achieves improved reliability while keeping the monitoring system relatively simple
Solution Approach 2:
The system replaces complex mechanical monitoring mechanisms with a sensor-based detection approach. The sensor optically or electronically detects electrode sheet positions and feeds data to a notification device, substituting mechanical complexity with simpler electronic sensing and processing
3Measurement precision
If sensor detection thresholds are set strictly to avoid false alarms, then measurement precision is maintained, but early abnormality detection capability deteriorates
Solution Approach 1:
The system changes the parameter being monitored from absolute position to positional deviation from reference position. By detecting deviations rather than absolute positions, the system maintains measurement precision while improving abnormality detection capability, as even small deviations from reference positions can indicate developing abnormalities
Data Source
AI summary
A notification determinator determines whether or not an inspection result of a winding body indicates defective on the basis of whether or not continuous positions of a first end surface and a second end surface indicated by first group data and second group data are separated from reference positions by a predetermined distance or more. In a case where the inspection result of the winding body indicates defective, a notification determinator performs a notification that inspection in an inspection machine is not performed normally, and outputs information indicating that a cause of the defect is a take-out chuck of an inspection machine or any of a plurality of winding cores to a display for maintenance.