JPH0573745A - Maintenance management device for manufacturing machine - Google Patents

Abstract

PURPOSE:To provide the maintenance management device of a manufacturing machine which automatically performs the maintenance management of the manufacturing machine. CONSTITUTION:The operation state of a manufacturing machine 10 is detected by a sensor 20, and this detected value is compared with a prescribed reference value by a diagnosing part 30. If the difference between the detected value and the reference value exceeds an allowable range, a maintenance request command indicating that maintenance is required is generated. The quality check of a product 40 is performed by a check device 50. Check information and operating information of the manufacturing machine 10 are reported to a host computer 100 through an operation recording part. Order reception data, preparation data, and maintenance parts data are inputted to the host computer 100. A schedule generating part 110 plans a manufacturing schedule based on order reception data and preparation data and plans a maintenance schedule based on the maintenance request command and maintenance parts data. Schedule information consisting of the manufacturing schedule and the maintenance schedule is given to the operation recording part 60 and is displayed on a display device 70.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a maintenance management device for a production machine, and more particularly to a function for automatically recognizing the time when maintenance is required based on the output of a sensor attached to the production machine and notifying the operator of this. Maintenance management device.

[0002]

2. Description of the Related Art Commercial production machines are often operated under severe operating conditions, and it is important to carry out appropriate maintenance so that they can always operate in good condition. For example, in an offset rotary press, roll-shaped paper is fed from a paper feed unit, printed in a printing unit, dried and cooled, and then cut or folded in a processing unit. Become. In order to perform such processing, the transport mechanism,
A rotating mechanism, a reciprocating mechanism, a heating mechanism, a cooling mechanism, and the like are used everywhere, and each of these drive mechanisms is forced to operate under severe operating conditions. In particular, in an offset rotary press, ink, paper dust, and the like are scattered during operation, so that they adhere to the air cylinder, the motor shaft, the cam mechanism, and the like. Then, the solidified ink lumps and paper powder lumps exert an operation load on these drive mechanisms. If this is left as it is, some kind of failure will occur eventually and the machine will have to be stopped.

In a production machine for business use, if the machine stops unexpectedly due to such a failure, serious problems will occur in the whole process, and the delivery time cannot be met. For this reason, conventionally, regular inspections have been performed to detect an abnormally occurring portion early and deal with it.

[0004]

However, since the frequency of periodical inspection is limited, an abnormality may occur before the next periodical inspection, and the production machine must be stopped. There is. In addition, manual periodic inspection requires a great deal of labor and time.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a production machine maintenance management device capable of automatically performing maintenance management of a production machine.

[0006]

[Means for Solving the Problems] (1) The first invention of the present application is, in a maintenance management device for a production machine, a sensor for detecting an operating state of the production machine and a detection value of the sensor compared with a predetermined reference value. However, if the difference between the two exceeds the allowable range, a diagnostic unit that issues a maintenance request command indicating that maintenance is required and a schedule creation unit that creates a maintenance schedule based on this maintenance request command are provided. It is provided.

(2) A second invention of the present application is, in a maintenance control device for a production machine, a sensor for detecting an operating state of the production machine and a detection value of the sensor are compared with a predetermined reference value. If the allowable range is exceeded, a diagnostic section that issues a maintenance request command indicating that maintenance is required, order data that indicates an order for a product, and the preparation status of the materials required for production are shown. A host computer that inputs and holds preparation data and maintenance parts data indicating the inventory of parts required for maintenance, a production schedule determined based on order data and preparation data input to this host computer, and a diagnostic unit A schedule creation section that creates a schedule including a maintenance schedule determined based on the maintenance request command given by the The production machine is operated and maintained based on the schedule.

(3) A third invention of the present application is the maintenance management device for a production machine according to the above-mentioned first or second invention,
An operation recording unit that records the operation status of the production machine is also provided.
The learning function is added to recognize the maintenance required time when performing maintenance on the production machine from the records in this operation recording unit and to refer to the past maintenance required time when the schedule creation unit creates the maintenance schedule. is there.

[0009]

[Operation] (1) According to the first invention of the present application, the operating state of the production machine is detected by the sensor, and by comparing the detected value with a predetermined reference value, it is automatically determined whether maintenance is necessary. Be recognized by. When maintenance is required, the schedule creation unit automatically creates a maintenance schedule. For this reason, it is not necessary to perform regular inspections by hand on the production machine.

(2) According to the second invention of the present application, the order data, the preparation data, and the maintenance parts data are input to the host computer. The schedule creation unit can formulate a production schedule and a maintenance schedule based on these data. Therefore, it is possible to operate and maintain the production machine based on an integrated schedule including the production schedule and the maintenance schedule.

(3) According to the third invention of the present application, an operation recording section is further provided. When the maintenance is actually performed, the time when the maintenance is performed is recorded in this operation recording unit. That is, the time required for a specific maintenance is recorded. By using the actual data of the maintenance required time, the schedule creation unit can more accurately make the maintenance schedule thereafter.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below based on illustrated embodiments. FIG. 1 is a block diagram showing the basic configuration of a maintenance management device for a production machine according to an embodiment of the present invention. The production machine 10 is a machine that is the target of maintenance management by this maintenance management device. Here, an example in which an offset rotary press is used as the production machine 10 will be described. The sensor 20
It is a sensor that detects the operating state of this production machine. Although the offset rotary press is equipped with various drive mechanisms, the sensor 20 is attached to each place where maintenance is required. The detection value of the sensor 20 is given to the diagnosis unit 30, where the detection value is compared with a predetermined reference value. The basic principle of diagnosis in the diagnosis unit 30 is to judge that maintenance is required when the difference between the detection value detected by the sensor 20 and a predetermined reference value exceeds a predetermined allowable value. ..

This diagnostic method will be described based on a more specific embodiment. For example, consider a case where a drive mechanism having an air cylinder 11 as shown in FIG. 2 is diagnosed. Now, it is assumed that the piston position when the air cylinder 11 is contracted is A, and the piston position when the air cylinder 11 is expanded is B. At this time, if the position sensor 21 is installed at the position of B in the figure, it can be recognized that the piston has reached B. Therefore, assuming that the piston is contracted, the air cylinder 11 is started to be driven at a predetermined time t0 to extend the piston, and the time t1 at which the sensor 21 detects the piston is measured.
The time t up to t1 is the time required for the piston to move from the position A to the position B. Sensor 21
Is provided with a function of detecting the movement time t, and the detection value of the sensor 21 is compared with a predetermined reference value in the diagnosis unit 30. This predetermined reference value is set in advance as a standard time required for the piston to move from position A to position B when the air cylinder 11 is operating normally. In this way, if the difference between the detected value of the sensor 21 and the reference value is large to some extent or more, it can be determined that some abnormality has occurred, and it can be recognized that maintenance is required. Specifically, when paper dust, ink, or the like adheres to the piston, the moving time from position A to position B becomes longer than the reference value. Therefore, when the detected value of the sensor 21 becomes longer than the reference value by a predetermined allowable amount or more, it can be recognized that maintenance such as cleaning of the piston is necessary.

FIG. 3 shows an example of a rotary drive system.
That is, the rotary encoder 22 is provided as a sensor for detecting the rotation speed of the motor 12. When the motor 12 is normally driven, the rotation speed should be constant with respect to the electric power W supplied to the motor 12. Therefore, this standard rotation speed is preset as a reference value. Then, the rotation speed when the supply power W is actually applied is detected from the rotary encoder 22, and the detected value is compared with the reference value. If the detected value is smaller than the reference value by a predetermined allowable amount or more, the motor 12
It can be determined that paper dust, ink, etc. are attached to the shaft, etc. and the operation load is applied, and it can be recognized that maintenance such as cleaning the shaft is necessary.

FIG. 4 shows an example of the edge position sensor of the running paper 13. In order to detect the edge position of the running paper 13, a sensor including a light emitting device 23a and a light receiving device 23b is used. Information on the edge position of the running paper 13 is obtained from the amount of light detected by the light receiver 23b.
Such sensors also require maintenance when used in harsh operating conditions. For example, the light emitter 23a and the light receiver 23
The detection value of the light receiver 23b decreases due to factors such as deterioration of the function of b itself and adhesion of paper powder or ink to the lens. In this case, with no running paper 13 at all,
The detection value of the light receiver 23b may be compared with a predetermined reference value. If the detected value is smaller than the reference value by a predetermined allowable amount or more, clean the lens or use the light emitter 2
It can be recognized that maintenance such as replacement of 3a or the light receiver 23b itself is necessary.

In addition to this, for example, if there is a heating mechanism or a cooling mechanism, a temperature sensor may be prepared and the actual detected temperature may be compared with a predetermined reference temperature. In short, the sensor 20 may be any sensor as long as it can detect the operating state of a predetermined portion of the production machine 10. Then, the sensor 20 in a normal operating state
It is only necessary to prepare the standard detection value of 1 as the reference value, and to compare the two in the diagnosis unit 30. As a result of the comparison, if the difference between the two is greater than or equal to the predetermined allowable amount, the diagnosis unit 30 determines that the host computer 100
Issue a maintenance request command to the. When the sensor 20 is provided in each part of the production machine 10, the detection value from each sensor 20 is compared with each reference value, and each separate maintenance request command is issued.

In this embodiment, an inspection device 50 for inspecting the quality of the product 40 produced by the production machine 10 is provided. More specifically, the production machine 10
When an offset rotary press is used as the product, the product 40 is a printed matter by this rotary press, and the inspection device 50 is a device for inspecting the print quality of this printed matter. The operation recording unit 60 inputs the operation information from the production machine 10 and the inspection information from the inspection device 50. The operation information is information indicating whether the production machine is in preparation, operation, suspension, or maintenance, and the inspection information indicates how many defective products 40 are produced as a result of the operation. It is information indicating whether or not it is included. The operation recording unit can obtain an operation record (for example, how many prints have been printed) based on the operation information, and can obtain defective data (for example, how many prints have been defective) based on the inspection information. You can ask. Therefore, the net result obtained by subtracting the defective data from the operation result can be obtained as the production information. This production information is reported to the host computer 100 together with the operation information. Further, these pieces of information can be displayed on the display 70 to notify the operator on the spot.

Order data, preparation data, and maintenance parts data are input to the host computer 100. The order data is data indicating an order to be produced by the production machine 10. For example, data indicating what kind of printed matter (content), by when (delivery date), and how many sheets should be printed (quantity). Is. The preparation data is data indicating the procurement conditions of the materials and materials necessary for producing the above-mentioned order contents. For example, it is data indicating whether or not necessary papers, inks, etc. are prepared as an inventory in the warehouse, and when insufficient materials and materials are received. Further, the maintenance part data is data indicating whether or not the parts required for performing maintenance on the production machine 10 are prepared as an inventory, and when they are in stock if they are not available. The sales staff member inputs the order data, and the materials staff member inputs the preparation data and maintenance parts data.

These data are stored in the host computer 1.
00 to the schedule creation unit 110. Schedule creation section 1
The schedule created by 10 is a production schedule and a maintenance schedule. The production schedule is created based on the order data and the preparation data. For example, when order data such as orders A, B, and C are given, in principle, a schedule for processing these in order of delivery date is planned. However, as a result of referring to the preparation data, if the materials for processing a specific order are not yet ready, such an order is scheduled to be postponed within the range of delivery date. .. Since various methods are known as such a schedule creation method, detailed description thereof will be omitted here. The features of the present invention are:
The schedule creating unit 110 has a function of creating a maintenance schedule. As described above, when a maintenance request command is given from the diagnosis unit 30 to the host computer 100, the maintenance request command is taken into the schedule creation unit 110. Based on this maintenance request command, the schedule creating unit 110 refers to the maintenance part data and makes a maintenance schedule. The production schedule and maintenance schedule created in this way are given to the host computer 100 as schedule information, and further displayed on the display 70 via the operation recording unit 60. The operator at the work site carries out production or maintenance work while looking at the schedule displayed on the display 70.

In this embodiment, a database for maintenance management is prepared in the diagnosis unit 30. In this database, as shown in the block of FIG. 1, four items of grace time, necessary parts, required time, and maintenance method are defined for each maintenance management target of the production machine 10. For example, for the air cylinder 11 shown in FIG.
If the difference between the detected value and the reference value is α1, the grace period is 1
A week, if α2, a grace period of 2 days can be set. As described above, the grace time is a value indicating that the maintenance needs to be performed within the period. The necessary parts are data indicating the necessary parts when performing maintenance on this maintenance management target. For example, when maintenance such as air cylinder 11 is required for cleaning, a cleaner required for cleaning is a necessary component, and the light emitter 23a,
When maintenance such as the light receiver 23b is necessary for replacement, a new light emitter 23a and a new light receiver 23b for replacement are required parts. The required time is data indicating the required time for performing the maintenance work on the maintenance management target.
In addition, the maintenance method is data indicating the actual maintenance method to the operator at the site. The maintenance request command given to the host computer 100 includes various data extracted from this database.

The schedule preparing section 110 can prepare a maintenance schedule based on the maintenance request command including such various data and the maintenance parts data indicating the inventory of the maintenance parts. The maintenance request command includes data indicating the grace time as described above. On the other hand, the order data includes data indicating the delivery date. Priorities can be determined based on the data indicating these times, and necessary maintenance schedules can be incorporated during the planned production schedule. Since the maintenance request command includes data indicating necessary parts, a reliable maintenance schedule can be planned by referring to this data and the maintenance part data. For example, the light receiver 2
When a maintenance request command indicating that it is necessary to replace 3b is issued, as a result of referring to the maintenance part data, the light receiver 23
If it can be recognized that there is no inventory of b at present and it is expected to arrive in one week, it is possible to make a maintenance schedule such that replacement is performed after the photoreceiver 23b, which is a necessary component, arrives.
Further, since the maintenance request command includes data indicating the time required for maintenance, it is possible to make a maintenance schedule in consideration of the scheduled end time of maintenance work.

As described above, the schedule information created by the schedule creating unit 110 includes, for example, order A (production planned) and order B.
(Production schedule), Maintenance X (Maintenance schedule), Order C (Production schedule), Maintenance Y (Maintenance schedule), ... Incorporating both the production schedule and maintenance schedule, and such schedule information. Is displayed 70 via the operation recording unit 60.
Displayed in. The operator at the site can operate the production machine 10 or perform maintenance while watching this instruction. Further, since the database prepared in the diagnosis unit 30 also includes data indicating the maintenance method, the maintenance method should be displayed on the display 70 when the operator at the site actually performs the maintenance. This will help the operator in maintenance work. It should be noted that in this embodiment, a learning function for appropriately updating the data regarding the required maintenance time is provided. That is, when the operator actually performs maintenance work, the fact that the production machine 10 is currently undergoing maintenance is given to the operation recording unit 60 as operation information. Therefore, the operation recording unit 60 can recognize the actual time required for maintenance. If the actual maintenance required time is reported to the diagnosis unit 30, the data regarding the maintenance required time in the database in the diagnosis unit 30 can be updated, and the database is used to learn the actual maintenance required time. The time required will be closer to the time required.

The present invention has been described above based on the illustrated embodiment, but the present invention is not limited to this embodiment and can be implemented in various modes other than this. For example, the embodiment of FIG. 1 shows the maintenance management device by functional blocks, and the hardware of each functional block can be appropriately changed in design. For example, the diagnosis unit 30 and the operation recording unit 60 can be configured by the same personal computer. The schedule creating unit 110 can be configured by a computer separate from the host computer 100, or can be implemented by software in the host computer 100. It is also possible to connect a plurality of sets of the production machine 10 and the diagnosis unit 30 shown in FIG. 1 to the host computer 100.

[0024]

As described above, according to the present invention, the operating state of a production machine is detected by a sensor, and the detected value is compared with a predetermined reference value to automatically recognize whether maintenance is required. Since the maintenance schedule is automatically created, the maintenance management of the production machine can be automatically performed.

[Brief description of drawings]

FIG. 1 is a block diagram showing a basic configuration of a maintenance management device for a production machine according to an embodiment of the present invention.

FIG. 2 is a diagram showing an example in which a sensor 20 in the device shown in FIG. 1 is applied to an air cylinder 11.

FIG. 3 is a diagram showing an example in which a sensor 20 in the device shown in FIG. 1 is applied to a motor 12.

4 is a diagram showing an example in which the sensor 20 in the device shown in FIG. 1 is applied to a light emitting device 23a and a light receiving device 23b.

[Explanation of symbols]

 10 ... Production machine 11 ... Air cylinder 12 ... Motor 13 ... Running paper 20 ... Sensor 21 ... Position sensor 22 ... Rotary encoder 23a ... Light emitter 23b ... Light receiver 30 ... Diagnostic unit 40 ... Product 50 ... Inspection device 60 ... Operation record Part 70 ... Display 100 ... Host computer 110 ... Schedule creation part

Claims (3)

[Claims] 1. A sensor for detecting an operating state of a production machine and a detection value of this sensor are compared with a predetermined reference value, and when a difference between the both exceeds an allowable range, it indicates that maintenance is required. A maintenance management device for a production machine, comprising: a diagnosis unit that issues a maintenance request command; and a schedule creation unit that creates a maintenance schedule based on this maintenance request command. 2. A sensor that detects an operating state of a production machine and a detection value of this sensor are compared with a predetermined reference value, and if the difference between the two exceeds an allowable range, it indicates that maintenance is required. Diagnostic department that issues maintenance request commands, order data that shows orders for products, preparation data that shows the preparation status of materials required for production, and maintenance parts data that shows the inventory of parts required for maintenance A host computer for inputting and holding, and a production schedule determined based on order data and preparation data input to the host computer, a maintenance request command given from the diagnostic unit, and the host computer A maintenance schedule determined based on the maintenance part data, and a schedule creation unit that creates a schedule including the maintenance schedule, and the operation and the operation of the production machine based on the created schedule. Maintenance apparatus for production machines, characterized in that to perform the protect. 3. The maintenance management device according to claim 1, further comprising an operation recording unit for recording an operation state of the production machine,
It is possible to recognize the maintenance required time when performing maintenance on the production machine from the record in this operation recording unit, and add a learning function that can refer to the past maintenance required time when the schedule creation unit creates the maintenance schedule. A characteristic maintenance device for production machines.