Note: Descriptions are shown in the official language in which they were submitted.
CA 02888334 2015-04-14
1
-
- = DESCRIPTION
Title of Invention: MAINTENANCE-PLAN-DEVELOPING SUPPORT
SYSTEM, MAINTENANCE-PLAN-DEVELOPING SUPPORT METHOD, AND
MAINTENANCE-PLAN-DEVELOPING SUPPORT PROGRAM
Technical Field
[0001]
The present invention relates
to a
maintenance-plan-developing support system, a
maintenance-plan-developing support method, and a
maintenance-plan-developing support program.
Background Art
[0002]
Maintenance business of plants, various work machines,
or various transportation machines is focused on prediction
maintenance (state monitoring and preservation) in which,
before a target object fails or stops, signs thereof are
observed and the target object is repaired. In recent years,
with the performance improvement of sensing apparatuses,
improvement in a network, or high performance of processing
devices, it has been possible to monitor a maintenance target
state in real time. In addition, a monitoring result obtained
in the above-described manner can be utilized in maintenance
341250548 eng final
CA 02888334 2015-04-14
2
=
business. As such a technique, the following thermal expansion
coefficients have been proposed.
[0003]
In other words, there has been proposed a failure
diagnosis system (refer to PTL 1) or the like which effectively
utilizes maintenance instance information including data
ambiguity or a portion of missing parts even incases when there
is not a sufficient amount of highly similar maintenance
instance information.
[0004]
In addition, it is also important to draft an efficient
maintenance plan including supply of components or maintenance
people in order to perform maintenance business rapidly and at
low cost. With regard thereto, there has been proposed a
maintenance work management system of a work machine (refer to
PTL 2) or the like which can predict the lifetime of a work
machine more accurately so as to draft an appropriate overhaul
execution plan early.
Citation List
Patent Literature
[0005]
PTL 1: JP-A-2011-170724
PTL 2: JP-A-2007-100305
Summary of Invention
Technical Problem
341250548 eng final
CA 02888334 2015-04-14
3
[ 0 0 6 ]
In recent years, the market of mining machines has rapidly
expanded according to high demand for resources. In
maintenance business of the mining machines, it is necessary
to optimize a global supply chain which connects mines scattered
worldwide (consumption regions) to warehouses (supply regions)
of mining machines, components, or the like, in order to
maximize a machine running rate. A component of the mining
machine is generally expensive and large-sized. In a case of
performing maintenance, it is problematic to determine which
transportation means the component is supplied by and from which
warehouse the component is supplied.
[0007]
In addition, it is necessary to effectively use a recycled
component obtained by repairing and reproducing a component
which has failed previously in order to optimize life cycle cost
of a mining machine.
[0008]
As mentioned above, at present, developing a maintenance
plan of a mining machine requires a wide range of knowledge and
experience and can thus be said to be business requiring highly
advanced skills. Currently, such highly advanced plan
developing business is personal business which depends on an
excellent maintenance plan developer. On the other hand, with
the rapid expansion of the market, deficiency of maintenance
341250548 eng final
CA 02888334 2015-04-14
4
- personnel and experience deficiency are problematic, and thus
it is hard to efficiently perform the above-described plan
developing business. These problems cannot be solved by the
techniques disclosed in PTLs 1 and 2.
[0009]
Therefore, an object of the present invention is to
provide a technique enabling an effective maintenance plan to
be efficiently developed without depending on a maintenance
person's skill or the like.
Solution to Problem
[0010]
In order to solve the above-described problems, according
to the present invention, there is provided a
maintenance-plan-developing support system including a
storage device that stores a first database holding information
regarding a phenomenon occurring in a work machine, information
regarding a failure occurring in the work machine after the
phenomenon occurs, and information regarding maintenance work
performed in relation to the failure in correlation with each
other, a second database holding information regarding standard
maintenance work defined for each work machine, a third database
holding information regarding possible running time of each
personnel member and each piece of equipment for maintenance
work, and a fourth database holding information regarding an
inventory and a price of a component used for maintenance work,
341250548 eng final
CA 02888334 2015-04-14
. or an old version or recycled component thereof, and
transportation destination-based and
transportation
means-based delivery date and transportation cost for each
warehouse; and a calculation device that performs a process of
5 receiving information regarding a phenomenon occurring in a
work machine at a certain location from a monitoring system of
the work machine via a network, collating the received
information regarding the phenomenon with the first database
so as to estimate a failure which may occur after the occurrence
of the phenomenon, and specifying information regarding
maintenance work performed on the work machine in relation to
the failure in the first database, a process of collating the
specified information regarding the maintenance work with the
second database, specifying information regarding standard
maintenance work expected to be performed on the work machine,
and specifying possible running time of personnel and equipment
for the maintenance work designated by the information
regarding the maintenance work as the maintenance execution
candidate date in the third database, and a process of stocking
a component designated by the information regarding the
maintenance work, or an old version or recycled component
thereof, specifying, in the fourth database, a warehouse to be
used when the delivery date falls in a grace period from the
present time to the maintenance execution candidate date in a
case where the component, or the old version or recycled
341250548 eng final
CA 02888334 2015-04-14
6
component thereof is delivered to a location of the work machine
by transportation means, the transportation means
corresponding to the delivery date, and a transportation cost,
generating, as maintenance plan information, information
pieces regarding the delivery date, the warehouse, the
transportation means, and the transportation cost of the
component, or the old version or recycled component thereof used
for the maintenance work, and information regarding the
maintenance execution candidate date, and outputting the
information to an output device.
Advantageous Effects of Invention
[0011]
According to the present invention, it is possible to
efficiently draft an effective maintenance plan without
depending on a maintenance person's skill or the like.
Brief Description of Drawings
[0012]
[Fig. 1] Fig. I is a configuration diagram of a network
including a maintenance-plan-developing support system in the
present embodiment.
[Fig. 2A] Fig. 2A is a diagram illustrating an example
of a phenomenon history database in the present embodiment.
[Fig. 2B] Fig. 2B is a diagram illustrating an example
of a failure history database in the present embodiment.
[Fig. 3] Fig. 3 is a diagram illustrating an example of
341250548 eng final
CA 02888334 2015-04-14
7
a work history database in the present embodiment.
[Fig. 4] Fig. 4 is a diagram illustrating an example of
a maintenance work database in the present embodiment.
[Fig. 5] Fig. 5 is a diagram illustrating an example of
a schedule database in the present embodiment.
[Fig. 6A] Fig. 6A is a diagram illustrating an example
of a component inventory table in a component supply database
of the present embodiment.
[Fig. 6B] Fig. 6B is a diagram illustrating an example
of a transportation means table in the component supply database
of the present embodiment.
[Fig. 6C] Fig. 6C is a diagram illustrating an example
of a compatible component table in the component supply database
of the present embodiment.
[Fig. 7A] Fig. 7A is a diagram illustrating an example
of an operation loss table in a customer knowledge database of
the present embodiment.
[Fig. 7B] Fig. 7B is a diagram illustrating an example
of a residual lifetime table in the customer knowledge database
of the present embodiment.
[Fig. 7C] Fig. 7C is a diagram illustrating an example
of a customer table in the customer knowledge database of the
present embodiment.
[Fig. 8] Fig. 8 is a diagram illustrating an example of
a periodic maintenance database of the present embodiment.
341250548 eng final
_ _
CA 02888334 2015-04-14
8
-
[Fig. 9] Fig. 9 is a diagram illustrating an example of
a component history database of the present embodiment.
[Fig. 10A] Fig. 10A is a diagram illustrating an example
of a running determination table in a component running database
of the present embodiment.
[Fig. 10B] Fig. 10B is a diagram illustrating an example
of a running result table in the component running database of
the present embodiment.
[Fig. 11A] Fig. 11A is a diagram illustrating an example
of an abnormality diagnosis result table in a maintenance plan
database of the present embodiment.
[Fig. 11B] Fig. 11B is a diagram illustrating an example
of a countermeasure extraction result table in the maintenance
plan database of the present embodiment.
[Fig. 11C] Fig. 11C is a diagram illustrating an example
of an execution candidate table in the maintenance plan database
of the present embodiment.
[Fig. 11D] Fig. 11D is a diagram illustrating an example
of a supply/operation plan table in the maintenance plan
database of the present embodiment.
[Fig. 121 Fig. 12 is a diagram illustrating an example
of a prediction result database of the present embodiment.
[Fig. 13] Fig. 13 is a flowchart illustrating a procedure
example 1 in a maintenance-plan-developing support method of
the present embodiment.
341250548 eng final
CA 02888334 2015-04-14
9
-
[Fig. 14] Fig. 14 is a flowchart illustrating a procedure
example 2 in the maintenance-plan-developing support method of
the present embodiment.
[Fig. 15] Fig. 15 is a flowchart illustrating a procedure
example 3 in the maintenance-plan-developing support method of
the present embodiment.
[Fig. 16] Fig. 16 is a flowchart illustrating a procedure
example 4 in the maintenance-plan-developing support method of
the present embodiment.
[Fig. 17] Fig. 17 is a flowchart illustrating a procedure
example 5 in the maintenance-plan-developing support method of
the present embodiment.
[Fig. 18] Fig. 18 is a flowchart illustrating a procedure
example 6 in the maintenance-plan-developing support method of
the present embodiment.
[Fig. 19A]
Fig. 19A is a diagram illustrating a
relationship between residual lifetime and a maintenance plan
execution candidate in the present embodiment.
[Fig. 19B]
Fig. 19B is a diagram illustrating a
relationship between residual lifetime, a load ratio, and an
operation loss in the present embodiment.
[Fig. 20] Fig. 20 is a diagram illustrating an output
screen example 1 in the present embodiment.
[Fig. 21] Fig. 21 is a diagram illustrating an output
screen example 2 in the present embodiment.
341250548 eng final
CA 02888334 2015-04-14
- [Fig. 22] Fig. 22 is a diagram illustrating an output
screen example 3 in the present embodiment.
[Fig. 23] Fig. 23 is a diagram illustrating an output
management unit which evaluates a maintenance plan in the
5 present embodiment.
[Fig. 24] Fig. 24 is a diagram illustrating an example
of a maintenance plan evaluation table in a plan evaluation
database of the present embodiment.
[Fig. 25] Fig. 25 is a diagram illustrating an example
10 of a maintenance selection history table in the plan evaluation
database of the present embodiment.
[Fig. 26] Fig. 26 is a flowchart illustrating a procedure
example of a maintenance plan evaluation method in the present
embodiment.
[Fig. 27] Fig. 27 is a diagram illustrating a
relationship between maintenance plan candidates and a Pareto
optimal solution set in the present embodiment.
[Fig. 28]
Fig. 28 is a diagram illustrating a
relationship between customer selection history and estimated
customer policy in the present embodiment.
[Fig. 29]
Fig. 29 is a diagram illustrating a
relationship between maintenance plan evaluation variables L1
and L2 in the present embodiment.
Description of Embodiments
[0013]
341250548 eng final
CA 02888334 2015-04-14
11
. _
"
Hereinafter, an embodiment of the present invention will
be described with reference to the drawings. Fig. 1 is a diagram
illustrating a configuration example of a network including a
maintenance-plan-developing system 100 in the present
embodiment. The maintenance-plan-developing system 100
illustrated in Fig. 1 is a computer system enabling an effective
maintenance plan to be efficiently developed without depending
on a maintenance person's skill.
[0014]
In the present embodiment, as an example of a work machine,
a large mining machine will be described. Regarding the mining
machine, as described above, the market thereof has rapidly
expanded according to high worldwide demand for resources, and
there is a phenomenon in which component supply performance of
a machine manufacturer side cannot keep up with market demand.
On the other hand, when maintenance of the mining machine is
performed, a skilled maintenance person skillfully deals with
various components and the like which have similar enough
function to be used in common and have different states or
origins, such as a brand-new component which is of the latest
version, an old version component on which a retroactive
countermeasure is not made, and a recycled component obtained
by repairing and reproducing a component which has failed.
However, the components having the various attributes are
stored in warehouses which are scattered on a worldwide scale,
341250548 eng final
CA 02888334 2015-04-14
12
and thus it is hard for an unskilled maintenance person to
accurately check an attribute, a location, an inventory, or the
like thereof and to incorporate the information in a mining
machine maintenance plan in the related art. According to the
maintenance-plan-developing support system 100 of the present
embodiment, even an uns killed maintenance person can accurately
employ components having various attributes and appropriately
develop a complex maintenance plan.
[0015]
The maintenance-plan-developing support system 100 is a
connected to a network 180 and can perform data communication
with a monitoring system 170 and a client terminal 190. In
addition, the monitoring system 170 is a computer system which
monitors a measurement value from a sensor 11 provided in a
mining machine 10, that is, monitors sensor data, or monitors
a parameter calculated by applying sensor data to an appropriate
algorithm and detects abnormality in the mining machine 10. The
monitoring system 170 detects abnormality when the sensor data
or the calculated parameter exceeds a predetermined threshold
value, and transmits information indicating that the
abnormality has been detected, to the
maintenance-plan-developing support system 100. The
above-described sensor 11 may be a sensor which measures, for
example, a motor rotation speed, pump internal pressure, a
temperature or vibrations of each location, and the like of the
341250548 eng final
CA 02888334 2015-04-14
13
- mining machine 10. In addition, the sensor 11 provided in the
mining machine 10 transmits sensor data to the monitoring system
170 by using a communication device provided in the mining
machine 10 or a communication device provided in the sensor 11.
[0016]
On the other hand, the client terminal 190 accesses the
maintenance-plan-developing support system 100, and performs
a process of receiving data input by a maintenance person with
a keyboard, a mouse, or the like, or a process of displaying
data obtained from the maintenance-plan-developing support
system 100 on a display or the like.
[0017]
Further, the maintenance-plan-developing system 100 has
the following hardware configuration.
The
maintenance-plan-developing system 100 includes a storage
device 115 constituted by an appropriate nonvolatile storage
device such as a hard disk drive; a memory 113 constituted by
a volatile storage device such as a RAM; a CPU 114 (calculation
device) which reads a program held in the storage device 115
to the memory 113 and executes the program so as to perform
collective control of the system and also to perform various
detection, calculation and control processes; and a
communication device 112 which is connected to the network 180
and performs communication with other devices.
[0018]
341250548 eng final
CA 02888334 2015-04-14
14
-
Functions realized by executing the above-described
program include a phenomenon diagnosis function 121, a failure
diagnosis function 122, a countermeasure extraction function
131, a plan creation function 141, a periodic maintenance plan
adjustment function 142, a lifetime calculation function 151,
and a downtime calculation function 152. In the example of the
maintenance-plan-developing support system 100 illustrated in
Fig. 1, a functional unit is exemplified which has a set of each
functional group and a database group storing data used in each
function. As such a functional unit, there are an abnormality
diagnosis unit 120, a countermeasure extraction unit 130, a plan
creation unit 140, a performance prediction unit 150, and an
output management unit 160. Transmission of data between the
respective functional units is managed by an I/0 111 via a bus.
The database of each functional unit will be described later.
[0019]
In addition, in the present embodiment, data is assumed
to be input and output by the client terminal 190, but the
maintenance-plan-developing support system 100 may have input
and output functions, and devices (a display, a keyboard, and
the like).
[0020]
Next, the functions of the maintenance-plan-developing
system 100 of the present embodiment will be described. As
described above, the following functions can be said to be
341250548 eng final
CA 02888334 2015-04-14
- functions realized by executing, for example, a program
included in the maintenance-plan-developing support system 100.
Details of databases in the description here will be described
later.
5 [0021]
The maintenance-plan-developing support system 100 has
a function of receiving information regarding a phenomenon
occurring in the mining machine 10 at a certain location from
the monitoring system 170 via the network 180, of collating the
10 received information regarding the phenomenon with a phenomenon
history database 123 or a failure history database 124 (both
of which are first databases) so as to estimate failures which
may occur after the phenomenon occurs, and of specifying
information regarding maintenance work performed on the mining
15 machine 10 in a work history database 132 (first database) when
the failure occurs.
[0022]
In addition, the maintenance-plan-developing support
system 100 has a function of collating the information regarding
the specified maintenance work with a maintenance work database
133 (second database) so as to specify information regarding
standard maintenance work which is expected to be performed on
the above-described mining machine 10, and of specifying the
time at which personnel and equipment for the maintenance work
designated by the information regarding the maintenance work
341250548 eng final
CA 02888334 2015-04-14
16
- ' can work, as the maintenance execution candidate date in a
schedule database 143 (third database).
[0023]
Further, the maintenance-plan-developing support system
100 has a function of stocking a component designated by the
above-described information regarding the maintenance work, or
an old version or recycled component thereof, of specifying,
in a component supply database 144 (fourth database), a
warehouse to be used when the delivery date falls in a grace
period from the present time to the maintenance execution
candidate date in a case where the corresponding component, or
the old version or recycled component thereof is delivered to
a location of the mining machine 10 by transportation means,
the transportation means corresponding to the delivery date,
and a transportation cost, of generating, as maintenance plan
information, information pieces regarding the delivery date,
the warehouse, the transportation means , and the transportation
cost of the component, or the old version or recycled component
thereof of specifying used for the maintenance work, and
information regarding the maintenance execution candidate date,
and of storing the information in a maintenance plan database
161 or outputting the information to the client terminal 190.
[0024]
Still further, the maintenance-plan--developing support
system 100 has a function of collating information regarding
341250548 eng final
CA 02888334 2015-04-14
17
= a load ratio of a component of the mining machine 10 or the
phenomenon occurrence location, included in the information
(originated from the monitoring system 170) regarding the
phenomenon of the mining machine 10 with a customer knowledge
database 145 (fifth database) so as to estimate a residual
lifetime of the component of the mining machine 10 or the
phenomenon occurrence location, of setting a load ratio which
is reduced according to an extent of the residual lifetime being
lower than the grace time from the present time to the
maintenance execution candidate date as a load ratio of the
mining machine 10, of specifying an economic loss at the load
ratio in the customer knowledge database 145 (fifth database),
and of storing the above-described maintenance plan information
including information regarding economic losses at the reduced
load ratio and the corresponding load ratio in the maintenance
plan database 161 or outputting the information to the client
terminal 190.
[0025]
Moreover, the maintenance-plan-developing support
system 100 has a function of specifying history of attachment
and detachment of the same type of component, or the same type
of old version or recycled component thereof as the component,
or the old version or recycled component thereof used for the
maintenance work indicated by the above-described maintenance
plan information in a component history database 153 (sixth
341250548 eng final
CA 02888334 2015-04-14
18
. database) , of calculating a period of time between the specified
attachment and detachment as a lifetime, and of storing the
above-described maintenance plan information including
information regarding the lifetime in the maintenance plan
database 161 or outputting the information to the client
terminal 190.
[0026]
In addition, the maintenance-plan-developing support
system 100 has a function of specifying the presence or absence
of information regarding a failure of the same type of component,
or the same type of old version or recycled component thereof
as the component, or the old version or recycled component
thereof used for the maintenance work indicated by the
above-described maintenance plan information in the failure
history database 124 (first database), of specifying
information regarding maintenance work performed on the failure
if there is the information regarding the failure in the work
history database 132 (first database), of calculating a period
of time from work start to work finish, indicated by the
information regarding the maintenance work, as downtime, and
of storing the above-described maintenance plan information
including information regarding the downtime in the maintenance
plan database 161 or outputting the information to the client
terminal 190.
[0027]
341250548 eng final
CA 02888334 2015-04-14
19
_
Further, the maintenance-plan-developing support system
100 has a function of specifying information regarding a
measurement value of the same type of component, or the same
type of old version or recycled component thereof as the
component, or the old version or recycled component thereof used
for the maintenance work indicated by the above-described
maintenance plan information in a running result table 1010
(seventh database) of a component running database 154, of
collating information regarding the specified measurement
value with a running determination table 1000 (eighth database)
of the component running database 154, of calculating a running
stop period of the component, or the old version or recycled
component thereof as downtime, and of storing the
above-described maintenance plan information including
information regarding the downtime in the maintenance plan
database 161 or outputting the information to the client
terminal 190.
[0028]
Still further, the maintenance-plan-developing support
system 100 has a function of determining whether or not a
schedule of periodic maintenance is included within a period
from the present time to the maintenance execution candidate
date indicated by the above-described maintenance plan
information in a periodic maintenance database 146 (ninth
database), of replacing the maintenance execution candidate
341250548 eng final
CA 02888334 2015-04-14
_
date with the periodic maintenance date if the schedule of the
periodic maintenance is included within the period to the
maintenance execution candidate date indicated by the
maintenance plan information, and of generating maintenance
5 plan information again.
[0029]
These functions will be described in detail in
correlation with the functional units of Fig. 1. The
abnormality diagnosis unit 120 included in the
10 maintenance-plan-developing support system 100 refers to and
compares a phenomenon history database 122 in which history of
phenomena having occurred in the mining machine 10 or the like
from the past is accumulated with sensor data received from the
monitoring system 170 or a parameter through the phenomenon
15 diagnosis function 121, and diagnoses what kind of phenomenon
corresponds to the abnormality of the mining machine 10 detected
by the monitoring system 170.
[0030]
The abnormality diagnosis unit 120 of the
20 maintenance-plan-developing support system 100 refers to and
compares the failure history database 124 in which history of
failures having occurred in the mining machine 10 or the like
from the past is accumulated with a phenomenon specified by the
phenomenon diagnosis function 121 through the failure diagnosis
function 122, and diagnoses what kind of sign of failure
341250548 eng final
CA 02888334 2015-04-14
21
corresponds to the phenomenon specified by the phenomenon
diagnosis function 121.
[0031]
In the above-described way, the abnormality diagnosis
unit 120 of the maintenance-plan-developing support system 100
specifies what kind of failure corresponds to the abnormality
detected by the monitoring system 170, by using the
above-described functional group. In addition, the phenomenon
diagnosis function 121 and the failure diagnosis function 122
of the abnormality diagnosis unit 120 transmit the specified
phenomenon and failure to the output management unit 160. The
output management unit 160 stores and manages the specified
phenomenon and failure in the maintenance plan database 161.
[0032]
In addition, the countermeasure extraction unit 130 of
the maintenance-plan-developing support system 100 refers to
and compares the work history database 132 in which history of
maintenance work for failures of the mining machine 10 or the
like from the past is accumulated with a failure specified by
the failure diagnosis function 122 through the countermeasure
extraction function 131, and extracts a countermeasure to be
taken for the abnormality detected by the monitoring system 170.
Further, a maintenance person's skill, equipment, work cost,
or work time required to perform maintenance work extracted from
the work history database 132 is extracted by referring to the
341250548 eng final
_ _
CA 02888334 2015-04-14
22
= maintenance work database 133 through the countermeasure
extraction function 131. Still further, through the
countermeasure extraction function 131, information regarding
the countermeasure to be taken, extracted as described above,
is transmitted to the output management unit 160. The output
management unit 160 stores and manages the information in the
maintenance plan database 161.
[0033]
In addition, the plan creation unit 140 of the
maintenance-plan--developing support system 100 extracts a
schedule of a corresponding maintenance person and equipment
from the schedule database 143 so as to extract the maintenance
execution candidate date, in relation to the countermeasure
extracted by the above-described countermeasure extraction
unit 130, through the plan creation function 141. Further, in
a case where the countermeasure extracted by the countermeasure
extraction unit 130 is maintenance work including component
exchange, a supply plan related to supply thereof is developed
by referring to the component supply database 144 through the
plan creation function 141. Details of this developing
procedure will be described later. Still further, through the
plan creation function 141, an operation plan is developed on
the basis of operation loss information and residual lifetime
information in the customer knowledge database 145. Details
of this developing procedure will be described later.
341250548 eng final
CA 02888334 2015-04-14
23
- Furthermore, the periodic maintenance schedule in the periodic
maintenance database 146, and a schedule of the above-described
supply plan and operation plan are adjusted so that a
maintenance schedule is adjusted, through the periodic
maintenance plan adjustment function 142 of the plan creation
unit 140. Details of this adjustment procedure will be
described later.
[0034]
The plan creation unit 140 transmits information
regarding the maintenance plan formed by the operation plan and
the supply plan developed through the plan creation function
141, the periodic maintenance plan adjustment function 142, and
the like, to the output management unit 160. The output
management unit 160 stores and manages the information in the
maintenance plan database 161.
[0035]
In addition, when the countermeasure extraction unit 130
recognizes that component exchange is necessary as the
countermeasure to be taken by the countermeasure extraction
unit 130, and a component to be used is specified by the plan
creation unit 140 in relation to the component exchange, the
performance prediction unit 150 refers to the history of work
for each component recorded in the component history database
153 so as to calculate a lifetime result of the component to
be used through the lifetime calculation function 151. Further,
341250548 eng final
CA 02888334 2015-04-14
24
- information regarding the calculated lifetime result is
transmitted to the output management unit 160 through the
lifetime calculation function 151. The output management unit
160 stores and manages the information in a predicted result
database 162. Still further, in this case, the performance
prediction unit 150 specifies a component of which a status is
in an exchanged state in the component history database 153,
that is, which has already reached the estimated lifetime, reads
failure history of the component from the failure history
database 124, and calculates downtime based on the failure
history, through the downtime calculation function 152.
Details of this calculation method will be described later.
Furthermore, simultaneously therewith, downtime of the
component to be used is calculated on the basis of a record of
a load ratio (sensor data obtained from the various sensors 11
provided in the mining machine 10) of each mining machine 10,
held in the component running database 154, through the downtime
calculation function 152. Details of this calculation method
will be described later.
[0036]
Through the downtime calculation function 152, it may be
determined whether or not there is a difference between the
downtime based on the failure history and the downtime based
on the sensor data, obtained as described above, a determination
result thereof may be transmitted to the client terminal 190
341250548 eng final
CA 02888334 2015-04-14
- so as to be presented to a user, and the user may select either
of the downtimes. Alternatively, through the downtime
calculation function 152, the user may modify either of the
downtimes by using the client terminal 190. The performance
5 prediction unit 150 transmits the downtime defined uniquely in
the above-described way to the output management unit 160. The
output management unit 160 stores and manages the downtime in
the predicted result database 162. In addition, the downtime
may be modified not only in the occurrence of abnormality in
10 the mining machine 10 but also in response to an instruction
from the user through the downtime calculation function 152 in
normal times.
[0037]
The output management unit 160 of the
15 maintenance-plan-developing support system 100 holds and
manages the above-described results output from the abnormality
diagnosis unit 120, the countermeasure extraction unit 130, and
the plan creation unit 140 in the maintenance plan database 161,
and holds and manages the above-described result output from
20 the performance prediction unit 150 in the predicted result
database 162. In addition, the data of the maintenance plan
database 161 or the predicted result database 162 is output to
the client terminal 190 which accesses the database via the
network 180. In this outputting, the content output to the
25 client terminal 190 may be changed according to a user' s request
341250548 eng final
CA 02888334 2015-04-14
26
_ .
from the client terminal 190.
[0038]
Next, a description will be made of the type of database
used by the maintenance-plan-developing support system 100 of
the present embodiment. Fig. 2A illustrates an example of the
phenomenon history database 123 in the present embodiment. The
phenomenon history database 123 is a database in which history
of phenomena observed in the mining machine 10 from the past
is accumulated. A data structure thereof is an aggregate of
records including a phenomenon ID 201 as a key, the occurrence
date and time 202, a site ID 203, a machine ID 204, a type name
205, a phenomenon code 206, phenomenon content 207, a part code
208, a part name 209, and n sensor data items 210.
[0039]
The above-described phenomenon ID 201 stores an ID for
uniquely specifying a phenomenon which was observed in the past
in the mining machine 10. The occurrence date and time 202
stores the date and time when a corresponding phenomenon
occurred. The site ID 203 stores an ID of a site where the mining
machine 10 in which the corresponding phenomenon was observed
was operated, that is, a mine. The machine ID 204 stores an
ID of the mining machine 10 in which the corresponding
phenomenon was observed. The type name 205 stores a type name
of the mining machine 10. The phenomenon code 206 stores a code
indicating the corresponding phenomenon, and the content of the
341250548 eng final
CA 02888334 2015-04-14
27
- ' phenomenon corresponding to the code is stored in the phenomenon
content 207. The part code 208 stores a code indicating a part
of the mining machine 10 in which the corresponding phenomenon
was observed, and the part name 209 stores the name of the part.
Each code described above and the content or the name indicated
by the code may be managed by creating a separate master table.
The n sensor data items 210 store information observed by the
respective sensors 11. The information stored in the sensor
data 210 may be information indicating the presence or absence
of abnormality, and may be a value itself observed by the sensor
11. In addition to the above-described sensor data 210, an
abnormality detection parameter calculated from one or a
plurality of sensor data items by the monitoring system 170 may
be stored in the phenomenon history database 123.
[0040]
Fig. 2B illustrates an example of the failure history
database 124. The failure history database 124 is a database
in which history of failures having occurred in the mining
machine 10 from the past is accumulated. The failure history
database 124 is an aggregation including a failure ID 211 as
a key, a phenomenon ID 212, the occurrence date and time 213,
a machine ID 214, a type name 215, a component serial number
216, a part code 217, a part name 218, a cause component number
219, cause-component recycled component determination 220, an
hour meter 221, a failure code 222, and failure content 223.
341250548 eng final
CA 02888334 2015-04-14
28
_
=
[0041]
The above-described failure ID 211 stores an ID for
uniquely specifying a failure which was observed in the past
in the mining machine 10. The phenomenon ID 212 stores an ID
for specifying a phenomenon observed in the mining machine 10
prior to the corresponding failure. The phenomenon ID 212 is
the same as the phenomenon ID 201 in the above-described
phenomenon history database 123. The occurrence date and time
213 stores the date and time when the corresponding failure
occurred. The machine ID 214 stores an ID of the mining machine
10 in which the corresponding failure occurred, and the type
name 215 stores a type name of the mining machine 10. The
component serial number 216 stores a number for uniquely
specifying a failure component in the mining machine 10. The
part code 217 and the part name 218 respectively store a code
indicating a failure part of the mining machine 10 and the name
thereof. The cause component number 219 stores a product number
of the failure component. The cause-component recycled
component determination 220 stores a flag for determining
whether the failure component is a recycled component or a
brand-new component. The hour meter 221 stores an indicative
value of an hour meter for measuring running time, provided in
the mining machine 10. The indicative value of the hour meter
is an indicative value at the time when the corresponding
component failed. The failure code 222 stores a code indicating
341250548 eng final
CA 02888334 2015-04-14
29
_
the content of the occurring failure, and the failure content
223 stores the content of the occurring failure. A relationship
between each code and the content of the above-described failure
history database 124 may also be managed by creating a separate
master table in the same manner as in the phenomenon or the part
of the phenomenon history database 123.
[0042]
Fig. 3 illustrates an example of the work history database
132 of the present embodiment. The work history database 132
is a database in which history of maintenance work performed
on failures having occurred in the mining machine 10 from the
past is accumulated. The work history database 132 is an
aggregate of records including a work ID 301 as a key, a failure
ID 302, handling start date and time 303, handling end date and
time 304, a machine ID 305, a failure code 306, failure content
307, a part code 308, a part name 309, a cause component serial
number 310, a cause component number 311, a work code 312, work
content 313, an exchanged component serial number 314, an
exchanged component number 315, and exchanged-component
recycled component determination 316. Among them, the failure
ID 302 is the same as that of the failure history database 124.
[0043]
The above-described work ID 301 stores an ID for
specifying work performed on a failure corresponding to the
failure ID 302. The handling start date and time 303 and the
341250548 eng final
CA 02888334 2015-04-14
_
handling end date and time 304 respectively store the time at
which the work starts and the time at which the work ends. The
machine ID 305 stores an ID of the mining machine 10 in which
the failure occurred and on which the maintenance work was
5 performed. The failure code 306 and the failure content 307
respectively store a code indicating the occurring failure and
the content thereof. The part code 308 and the part name 309
respectively store a code indicating a part in which the failure
occurred and the name thereof. The cause component serial
10 number 310 stores a number for uniquely specifying the failure
component, and the cause component number 311 stores a product
number thereof. The work code 312 stores a code corresponding
to the content of the performed maintenance work, and the work
content 313 stores the content of the maintenance work. In a
15 case where the maintenance work includes component exchange,
an ID of a new component attached to the mining machine 10 instead
of the failure component is stored in the exchanged component
serial number 314. The exchanged component number 315 stores
a product number of the exchanged component, and the
20 exchanged-component recycled component determination 316
stores a flag indicating whether or not the component is a
recycled component.
[0044]
The respective history databases of which the examples
25 are illustrated in Figs. 2A and 3 correspond to a first database
341250548 eng final
CA 02888334 2015-04-14
31
-
in the present invention, and are created and managed by a
maintenance business execution person and are continuously
expanded as a result of maintenance business being performed.
[0045]
Fig. 4 illustrates an example of the maintenance work
database 133 in the present embodiment. The maintenance work
database 133 corresponds to a second database in the present
invention, which holds information regarding standard
maintenance work defined for each work machine. The
maintenance work database 133 is a database storing information
regarding a resource or cost necessary in standard maintenance
work performed for each type of mining machine 10. The
maintenance work database 133 is an aggregate of records
including a type name 401 as a key, a work code 402, work content
403, a part code 404, a part name 405, a component number 406,
an exchanged component number 407, work cost 408, standard work
time 409, necessary equipment 410, and necessary maintenance
person's skill 411.
[0046]
The above-described type name 401 stores a type name of
the mining machine 10 which is a maintenance work target. The
work code 402 and the work content 403 respectively store a code
for specifying work content and the content thereof. The part
code 404, the part name 405, and the component number 406
respectively store a code indicating a target part on which the
341250548 eng final
CA 02888334 2015-04-14
32
_
maintenance work is performed in the mining machine 10, the name
thereof, and a product number of a target component. The work
code 402 may differ in a case where cost, work time, or a
necessary resource differs depending on the type or a part of
the mining machine 10, or a component difference, even in the
same work content. The exchanged component number 407 stores
a product number of a newly attached component in a case where
component exchange is performed in the maintenance work. On
the other hand, in a case where component exchange is not
performed in the maintenance work, the exchanged component
number 407 is blank, or stores a predetermined determination
symbol. The work cost 408, the standard work time 409, the
necessary equipment 410, and the necessary maintenance person' s
skill 411 respectively store cost necessary in the maintenance
work, time necessary in the maintenance work, the name of
equipment necessary in the maintenance work, and the name of
a maintenance person with the necessary skill in the maintenance
work.
[0047]
Fig. 5 illustrates an example of the schedule database
143 in the present embodiment. The schedule database 143
corresponds to a third database in the present invention which
holds information regarding the possible running time of each
personnel member and each piece of equipment for maintenance
work. The schedule database 143 is an aggregate of records
341250548 eng final
_
CA 02888334 2015-04-14
33
_ .
- including the date 500, a maintenance person schedule 501, and
an equipment schedule 502. The schedule database 143 can be
said to be a database which stores schedules of pieces of
equipment held by a maintenance service provider and
maintenance people employed thereby. In the example of the
schedule database 143 illustrated in Fig. 5, a period in which
the equipment and the maintenance person can correspond to
maintenance work is indicated by "1", and a period in which the
equipment and the maintenance person cannot correspond to
maintenance work is indicated by "0". In addition, in the
example of the schedule database 143 illustrated in Fig. 5, the
date 500 is denoted per day, but may be arbitrarily set, for
example, per hour, in the unit of eight hours, or per week, by
a manager or the like of maintenance work.
[0048]
Fig. 6A illustrates an example of a component inventory
table 600 included in the component supply database 144 of the
present embodiment. The component supply database 144
includes the component inventory table 600, a transportation
means table 610, and a compatible component table 620, and
corresponds to a fourth database in the present invention which
holds information regarding an inventory, a price, and a
transportation destination-based and
transportation
means-based delivery date and transportation cost of each
component used for maintenance work, or an old version component
341250548 eng final
CA 02888334 2015-04-14
34
or recycled component thereof, for each warehouse.
[0049]
The component inventory table 600 is an aggregate of
records including a part code 601, a part name 602, a component
number 603, recycled component determination 604, a warehouse
605, an inventory 606, and a price 607. Each record indicates
the number of certain components to be stocked, a location of
the certain component, and a price thereof. The part code 601,
the part name 602, the component number 603, and the recycled
component determination 604 are information regarding
associated attributes of a stocked component. Components for
exchange used for maintenance of the mining machine 10 include
a brand-new component which is of the latest version, an old
version component on which a retroactive countermeasure is not
made, and a recycled component obtained by repairing and
reproducing a component which has failed, as described above.
Among them, the recycled component is ranked depending on a
degree of consumption. Here, a brand-new component is denoted
by "N", and a recycled component is denoted by "Re-A", "Re-B",
and "Re-C" from a low degree of consumption, that is, from the
higher rank. The old version component just has an old type
number and is an unused new product, and is thus denoted by "N"
in the example of Fig. 6A, but denotation for specifying the
old version component may be performed. The warehouse 605
stores the name of a warehouse in which a stocked component is
341250548 eng final
CA 02888334 2015-04-14
= stored, the inventory 606 stores the number of stocked
components, and the price 607 stores a unit price of a stocked
component. The inventory 606 and the price 607 are variables
which change over time, but are assumed to store the latest
5 values at all times here.
[0050]
Fig. 6B illustrates an example of the transportation
means table 610 included in the component supply database 144
of the present embodiment. The transportation means table 610
10 included in the component supply database 144 is an aggregate
of records including a warehouse 611, a transportation
destination 612, transportation means 613, the delivery date
614, and transportation cost 615. This record indicates the
kind of transportation means, the required time, and the cost
15 from a warehouse which is a transportation source to a site which
is a transportation destination. Among them, the warehouse 611
stores the name of a warehouse which is a transportation source
of a component. The transportation destination 612 stores the
name of a site which is a transportation destination of a
20 component. The transportation means 613 stores the name of
means used for component transportation. The delivery date 614
and the transportation cost 615 respectively store the delivery
date and cost in each case.
[0051]
25
Fig. 6C illustrates an example of the compatible
341250548 eng final
CA 02888334 2015-04-14
36
component table 620 included in the component supply database
144 of the present embodiment. The compatible component table
620 included in the component supply database 144 is an
aggregate of records including a type name 621, a part code 622,
apart name 623, a component number 624, and a periodic exchange
interval 625. This record indicates a list of compatible
components which can be used in a certain component of the mining
machine 10, and a periodic exchange interval thereof. Among
them, the type name 621 stores information indicating a type
name of the target mining machine 10, the part code 622 stores
information for specifying a target part of the mining machine
10, and the part name 623 stores the name of a part indicated
by the part code 622. The target mining machine 10 and part
thereof can be specified on the basis of the respective
information pieces such as the type name 621, the part code 622,
and the part name 623. The component number 624 stores a product
number of a component which can be attached to and used in a
part of the target mining machine 10. As a component which is
applicable to a predetermined part of a certain mining machine
10, specified by the respective information pieces such as the
type name 621, the part code 622, and the part name 623, there
are three kinds of components including a brand-new component
of which a type number is the latest, an old version component
thereof, and a recycled component, which are substantially the
same in terms of specifications or functions. The periodic
341250548 eng final
CA 02888334 2015-04-14
37
exchange interval 625 stores a component exchange interval
which is recommended by a component manufacturer.
[0052]
Fig. 7A illustrates an example of an operation loss table
700 included in the customer knowledge database 145 of the
present embodiment. The customer knowledge database 145
corresponds to a fifth database in the present invention which
holds information pieces regarding residual lifetime for each
load ratio during a failure and an economic loss in a user of
the mining machine 10 due to a reduction in the load ratio, of
each mining machine 10, in correlation with each other. The
customer knowledge database 145 includes the operation loss
table 700, a residual lifetime table 710, and a customer table
730. A customer is a user of the mining machine 10 and is a
customer of a maintenance service of the mining machine 10.
[0053]
The operation loss table 700 is an aggregate of records
including a customer ID 701, a site ID 702, a type name 703,
a part code 704, a part name 705, a load ratio 706, and an
operation loss 707. The operation loss table 700 indicates an
economic loss of a certain customer, generated when a load ratio
of a certain part of the mining machine 10 is restricted at a
certain site.
[0054]
The customer ID 701 stores an ID for specifying a customer,
341250548 eng final
CA 02888334 2015-04-14
38
. .
and the site ID 702 stores an ID for specifying a site where
the mining machine 10 is operated. The type name 703, the part
code 704, and the part name 705 respectively store a type name
of the mining machine 10, a code indicating a part thereof, and
the name of the part. The load ratio 706 stores a load
restriction ratio in a case where a load on the mining machine
in normal rating running is set to 100. Here, for example,
if the "part" is a motor, the "load" corresponds to a rotation
speed or a torque. The operation loss 707 stores information
10 regarding an economic loss per hour of a customer operating the
mining machine 10, generated when a restriction is put on a load.
The operation loss 707 is characterized by an operation policy
of a customer, the kind of resource mined at a site, or a part
on which a load is restricted.
[0055]
Fig. 7B illustrates an example of the residual lifetime
table 710 included in the customer knowledge database 145 of
the present embodiment. The residual lifetime table 710 is an
aggregate of records including a customer ID 711, a site ID 712,
a type name 713, a part code 714, a part name 715, a phenomenon
code 716, phenomenon content 717, a failure code 718, failure
content 719, a load ratio 720, and residual lifetime 721.
[0056]
Among them, the customer ID 711 stores an ID for
specifying a customer, and the site ID stores an ID for
341250548 eng final
CA 02888334 2015-04-14
39
. .
specifying a site. The type name 713, the part code 714, and
the part name 715 respectively store a type name of the target
mining machine 10, a code indicating a part thereof, and the
name of the part. The phenomenon code 716 and the phenomenon
content 717 respectively store a code indicating a phenomenon
which occurred at a corresponding part and the content of the
phenomenon corresponding thereto. The failure code 718 and the
failure content 719 respectively store a code indicating a
failure to the phenomenon and the content of the failure. The
load ratio 720 stores a load ratio of a corresponding part of
the mining machine 10, which can be specified by the type name
713, the part code 714, and the part name 715. The residual
lifetime 721 stores a period of time until a failure occurs after
abnormality is detected at the corresponding part. The
residual lifetime 721 indicates that a failure stored in the
failure code 718 and the failure content 719 occurs at a certain
time if the corresponding part is run at a load ratio of the
load ratio 720 when a phenomenon corresponding to the phenomenon
code 716 and the phenomenon content 717 occurs at a part
designated by the part code 714 and the part name 715, of the
mining machine 10 having the type name 713 operated by a customer
designated by the customer ID 711 in a site designated by the
site ID 712.
[0057]
Fig. 7C illustrates an example of the customer table 730
341250548 eng final
CA 02888334 2015-04-14
= included in the customer knowledge database 145 of the present
embodiment. The customer table 730 is an aggregate of records
including a customer ID 731, a customer name 732, a site ID 733,
a site name 734, a site type 735, and a country name code 736.
5 Among them, the customer ID 731 is an ID for specifying a customer,
the customer name 732 stores the name of the customer, the site
ID 733 stores an ID for specifying a site operated by the customer,
the site name 734 stores the name of the site, the site type
735 stores the kind of resource mined in the site, and the country
10 name code 736 stores a country name code indicating a country
where the site is present. In the operation loss table 700,
the residual lifetime table 710, and the customer table 730,
the records thereof can be correlated with each other with the
customer ID and the site ID as keys.
15 [0058]
Fig. 8 illustrates an example of the periodic maintenance
database 146 of the present embodiment. The periodic
maintenance database 146 corresponds to a ninth database in the
present embodiment which stores a schedule of periodic
20 maintenance which is planned by a maintenance service provider
in relation to the mining machine 10. In
the periodic
maintenance database 146 exemplified in Fig. 8, the date for
which periodic maintenance is planned is denoted by "1", and
the date for which periodic maintenance is not planned is
25 denoted by "0". The unit of a schedule may be arbitrarily set
341250548 eng final
CA 02888334 2015-04-14
41
by a user in the same manner as in the schedule database 143
exemplified in Fig. 5.
[0059]
Fig. 9 illustrates an example of the component history
database 153 of the present embodiment. The component history
database 153 corresponds to a sixth database in the present
embodiment which stores information regarding attachment of
each component, or an old version or recycled component thereof
to the mining machine 10 and detachment from the mining machine
10. The component history database 153 is an aggregate of
records including a component serial number 901, a part code
902, apart name 903, a component number 904, recycled component
determination 905, a customer ID 906, a site ID 907, an
attachment machine ID 908, a situation flag 909, the attachment
date and time 910, and the detachment date and time 911.
[0060]
Among them, the component serial number 901 stores a
number for uniquely specifying a component on which a
maintenance service provider performs maintenance. The part
code 902 and the part name 903 respectively store a code
indicating a part to which the component is attached, and the
name of the part. The component number 904 and the recycled
component determination 905 respectively store a product number
and a recycled component determination flag of the component
designated by the above-described component serial number 901.
341250548 eng final
CA 02888334 2015-04-14
42
. .
The component goes on sales as a recycled component through a
cycle of attachment, detachment, recycle, and attachment. In
this process, the recycled component is ranked depending on a
degree of consumption as described above. The recycled
component tends to be ranked lower in the recycled component
determination 905 as the recycle is repeatedly performed.
[0061]
Respective records of the component serial numbers
"100100-103", "100100-151", "100100-182", "100100-213" of Fig.
9 show an example of a cycle of attachment, detachment, recycle,
attachment... of a certain component. A relationship between the
respective records shows a state in which a component of the
same part is repeatedly used.
[0062]
In the present embodiment, attachment and detachment of
a component is called a lifetime. This lifetime is managed by
giving different component serial numbers 901 even to a
component of the same part so as to be differentiated for each
recycle opportunity. The attachment machine ID 909 stores an
ID of the mining machine 10 to which the component is attached.
The customer ID 907 and the site ID 908 respectively store an
ID of a customer operating the mining machine 10 and an ID of
a site where the mining machine 10 is run. The situation flag
910 stores the present status of the component. The attachment
date and time 911 and the detachment date and time 912
341250548 eng final
CA 02888334 2015-04-14
43
respectively store the date and time at which the component is
attached to the mining machine 10 and the date and time at which
the component is detached from the mining machine 10.
[0063]
Fig. 10A illustrates an example of the running
determination table 1000 included in the component running
database 154 of the present embodiment. The component running
database 154 stores information for determining running or
stopping of a component by using a value obtained from the sensor
11 attached to the component, and includes the running
determination table 1000 which stores a determination
expression for determining whether or not a component attached
to a certain part of the mining machine 10 is run, and the running
result table 1010 which stores sensor data regarding the mining
machine 10 during a period designated by a user. The component
running database 154 of the present embodiment relates to a
motor designated by the component serial number
901="100100-103" of the component history database 153 (Fig.
9).
[0064]
The running determination table 1000 illustrated in Fig.
10A includes respective information pieces of a type name 1001,
a part code 1002, a part name 1003, a determination item 1004,
a determination value 1005, and a determination condition 1006.
For example, if the part name 1003 of a running determination
341250548 eng final
CA 02888334 2015-04-14
44
= =
= ' target is a "motor", the determination item 1004 is a value
such
as a rotation speed or a torque. In the running determination
table 1000 of Fig. 10A, a "running" period is determined in a
condition in which a "rotation speed" of the determination item
1004 is equal to or higher than "2000" as the determination value
1005.
[ 0065]
Fig. 10B illustrates an example of the running result
table 1010 included in the component running database 154 of
the present embodiment. The running result table 1010 is an
aggregate of records including the component serial number 1011,
an item 1012, a period 1013, and an average value 1014. Among
them, the component serial number 1011 stores a component number
for uniquely identifying a component on which measurement is
performed by the sensor 11. The item 1012 stores the type of
sensor data which is stored in relation to the component. The
period 1013 stores information regarding a period in which the
sensor 11 performs measurement on the component indicated by
the component serial number 1011. The average value 1014 stores
an average value in the period 1013, of sensor data items
measured by the sensor 11 in relation to the component indicated
by the component serial number 1011. In the present embodiment,
the period 1013 is set per hour, but may be changed as appropriate
through a user's operation.
[ 0 0 6 6 ]
341250548 eng final
CA 02888334 2015-04-14
'
Fig. 11A illustrates an example of an abnormality
diagnosis result table 1100 included in the maintenance plan
database 161 of the present embodiment. The maintenance plan
database 161 includes the abnormality diagnosis result table
5 1100, a countermeasure extraction result table 1120, an
execution candidate table 1130, and a supply/operation plan
table 1140. The tables 1100 to 1140 are created by using output
results from the abnormality diagnosis unit 120, the
countermeasure extraction unit 130, the plan creation unit 140,
10 and the performance prediction unit 150.
[0067]
The abnormality diagnosis result table 1100 is a table
output by the abnormality diagnosis unit 120, and is an
aggregate of records including an abnormality ID 1101, the
15 occurrence date and time 1102, an hour meter 1103, a customer
ID 1104, a site ID 1105, a machine ID 1106, a component serial
number 1107, a phenomenon code 1108, phenomenon content 1109,
a failure code 1110, and failure content 1111.
[0068]
20 The abnormality ID 1101 stores an ID for uniquely
specifying an abnormality which is specified by the
above-described abnormality diagnosis unit 120 and is regarded
as a sign of a failure. The occurrence date and time 1102 and
the hour meter 1103 respectively store values of the date and
25
time at which the abnormality was detected and a value of the
341250548 eng final
CA 02888334 2015-04-14
46
. _
hour meter. The customer ID 1104, the site ID 1105, the machine
ID 1106, and the component serial number 1107 respectively store
an ID for specifying a customer holding the mining machine 10
in which the abnormality was detected, an ID for specifying a
site where the mining machine 10 is run, an ID for specifying
the mining machine 10, and an ID for specifying a component in
which abnormality was detected. The phenomenon code 1108 and
the phenomenon content 1109 store results diagnosed through the
above-described phenomenon diagnosis function 121, and the
failure code 1110 and the failure content 1111 store results
diagnosed through the failure diagnosis function 122.
[0069]
Fig. 11B illustrates an example of the countermeasure
extraction result table 1120 included in the maintenance plan
database 161 of the present embodiment. The countermeasure
extraction result table 1120 is output by the above-described
countermeasure extraction unit 130, and is an aggregate of
records including a countermeasure ID 1121, an abnormality ID
1122, a work code 1123, work content 1124, standard work time
1125, work cost 1126, necessary equipment 1127, and a necessary
maintenance person's skill 1128.
[0070]
Among them, the countermeasure ID 1121 stores an ID for
uniquely specifying a countermeasure planned with respect to
the abnormality corresponding to the abnormality ID 1101 in the
341250548_eng final
CA 02888334 2015-04-14
47
= above-described abnormality diagnosis result table 1100, that
is, maintenance work. The abnormality ID 1122 stores the same
abnormality ID 1122 as the ID in the abnormality ID 1101 of the
above-described abnormality diagnosis result table 1100. The
work code 1123 and the work content 1124 respectively store a
code of the maintenance work extracted from the work history
database 132 and the content thereof. The standard work time
1125, the work cost 1126, the necessary equipment 1127, and the
necessary maintenance person's skill 1128 respectively store
information pieces regarding time, cost, equipment, and a
maintenance person's skill necessary in the maintenance work,
extracted from the maintenance work database 133 in relation
to the maintenance work.
[0071]
Fig. 11C illustrates an example of the execution
candidate table 1130 included in the maintenance plan database
161 of the present embodiment. The execution candidate table
1130 is a table which is extracted and output from the
countermeasure extraction result table 1120 output by the
countermeasure extraction unit 130 and the schedule database
143 through the planning function 141 of the plan creation unit
140. The execution candidate table 1130 is an aggregate of
records including a schedule ID 1131, a countermeasure ID 1132,
an execution candidate 1133, the execution possible date 1134,
a handling maintenance person 1135, handling equipment 1136,
341250548 eng final
CA 02888334 2015-04-14
48
. _
- - and tx 1137.
[0072]
Among them, the schedule ID 1131 stores an ID for
specifying a candidate period in which the maintenance work is
performed. The countermeasure ID 1132 is the same as the
countermeasure ID 1121 of the above-described countermeasure
extraction result table 1120 and stores an ID for specifying
a countermeasure to be performed. The execution candidate 1133
stores a value matching the schedule ID 1131. The execution
date 1134 stores a schedule which is extracted through the
above-described plan creation function 141 and in which the
maintenance work can be performed. The maintenance person 1135
and the equipment 1136 respectively store the name of a
maintenance person and the name of equipment corresponding to
the handling. The tx 1137 stores a grace period from the present
time to the execution candidate date of the maintenance work.
[0073]
Fig. 11D illustrates an example of the supply/operation
table 1140 included in the maintenance plan database 161 of the
present embodiment. The supply/operation table 1140 stores
results which are output by referring to the stocked component
database 145 and the customer knowledge database 145 through
the plan creation function 141 of the above-described plan
creation unit 140. The supply/operation plan table 1140
illustrated in Fig. 11D is a table configuration example
341250548_eng final
CA 02888334 2015-04-14
49
= indicating the content planned with respect to maintenance work
including component exchange work.
[0074]
The supply/operation table 1140 is an aggregate of
records including a plan ID 1141, a schedule ID 1142, a component
number 1143, recycled component determination 1144, a warehouse
1145, transportation means 1146, the delivery date 1147, a
component price 1148, a transportation cost 1149, a load ratio
1150, an operation loss 1151, and a work loss 1152.
[0075]
Among them, the plan ID 1141 stores an ID for uniquely
specifying a supply/operation plan. In addition, in a case
where the maintenance work does not include component exchange
and thus component supply is not necessary, the plan ID 1141
is an ID for specifying an operation plan.
[0076]
The schedule ID 1142 stores an ID corresponding to the
schedule ID 1131 of the above-described execution candidate
table 1130. The component number 1143 and the recycled
component determination 1144 respectively store a component
number of a newly attached component through component
exchanging work and a recycled component determination flag of
the component. In a case where the maintenance work does not
include the component exchanging work, the component number
1143 and the recycled component determination 1144 are blank
341250548 eng final
CA 02888334 2015-04-14
' or store arbitrary determination symbols.
[0077]
The warehouse 1145, the transportation means 1146, the
delivery date 1147, the component price 1148, and the
5 transportation cost 1149 respectively store the name of a
warehouse for supplying a component for exchange,
transportation means, the delivery date, a price of the
component, and cost required in transportation thereof. In a
case where the maintenance work does not include the component
10 exchanging work, in the same manner as in the component number
1143 and the recycled component determination 1144 described
above, the warehouse 1145, the transportation means 1146, the
delivery date 1147, the component price 1148, and the
transportation cost 1149 are blank or store arbitrary
15 determination symbols.
[0078]
The load ratio 1150 stores an upper limit of a load ratio
of a corresponding part (a component exchange target part) in
the mining machine 10 when maintenance is planned. The
20 operation loss 1151 stores an economic loss of the customer,
generated when a load on the mining machine 10 is restricted
to a value indicated by the load ratio 1150. The work loss 1152
stores an economic loss of the customer generated due to running
stop of the mining machine 10 during execution of the
25 maintenance work. The supply/operation table 1140 may be
341250548 eng final
CA 02888334 2015-04-14
51
= divided into a supply table related to supply of components and
an operation table related to operations such as a load ratio
or an operation loss and may be managed.
[0079]
Fig. 12 illustrates an example of the predicted result
database 162 of the present embodiment. The predicted result
database 162 is an aggregate of records including a target 1201,
a part code 1202, a part name 1203, a component number 1204,
recycled component determination 1205, a periodic exchange
interval 1206, average lifetime 1207, history base average
downtime (DT) 1208, running base average DT 1209, and the number
of samples 1210. These records are output results obtained
through the lifetime calculation function 151 and the downtime
calculation function 152 of the performance prediction unit
150.
[0080]
Among them, the target 1201 is designated by a country
code, a customer ID, or a site ID indicating the corresponding
mining machine 10 by specifying a range of the mining machine
10 which is a performance prediction target through the
above-described lifetime calculation function 151 and downtime
calculation function 152. In the example illustrated in Fig.
12, a value of a site ID is set as the target 1201. The part
code 1202 and the part name 1203 respectively store a code
indicating a part which is a performance prediction target and
341250548 eng final
CA 02888334 2015-04-14
52
- the name thereof. The component number 1204 and the recycled
component determination 1205 respectively store a product
number of a component which is a performance prediction target
and a recycled component determination flag.
[0081]
The periodic exchange interval 1206 stores a periodic
exchange interval of a component which is a performance
prediction target, that is, a component indicated by the
component number 1204. A value of the periodic exchange
interval 1206 is, for example, a value of a periodic exchange
interval on design defined by a component manufacturer. The
average lifetime 1207 stores a value of an average lifetime
calculated on the basis of the component history database 153
through the above-described lifetime calculation function 151.
A value of the average lifetime 1207 is a comparison target with
the above-described value of the periodic exchange interval
1206.
[0082]
The history base average DT 1208 stores a value of average
downtime calculated on the basis of the component history
database 153 and the failure history database 124 through the
downtime calculation function 152. The running base average
DT 1209 stores a value of average downtime calculated on the
basis of the component history database 153 and the component
running database 154 through the downtime calculation function
341250548 eng final
CA 02888334 2015-04-14
53
152. The number of samples 1210 stores the number of components
which are set as processing targets through the lifetime
calculation function 151 and the downtime calculation function
152.
[0083]
Hereinafter, a description will be made of actual
procedures of a maintenance plan developing method in the
present embodiment with reference to the drawings. Various
operations corresponding to the maintenance plan developing
method described below are realized by a program which is read
to the memory 113 and is executed by the
maintenance-plan-developing system 100. In addition, such a
program is formed by codes for performing various operations
described below.
[0084]
Fig. 13 is a flowchart illustrating a processing
procedure example 1 of the maintenance plan developing method
in the present embodiment. The flow is started when the
monitoring system 170 notifies the
maintenance-plan-developing support system. 100 that a value of
sensor data from the sensor 11 exceeds a predetermined threshold
value.
[0085]
First, a process in step S1301 is performed through the
phenomenon diagnosis function 121 of the abnormality diagnosis
341250548 eng final
CA 02888334 2015-04-14
54
= -
unit 120. Through the phenomenon diagnosis function 121,
abnormality of a certain component based on sensor data detected
by the monitoring system 170 is compared with the sensor data
210 of the phenomenon history database 123 so that a phenomenon
detected by the monitoring system 170 is specified, and
information regarding the phenomenon, such as the corresponding
phenomenon ID 201, phenomenon code 206 and phenomenon content
207 is extracted from the phenomenon history database 123.
[0086]
The information regarding the phenomenon specified in the
above-described way through the phenomenon diagnosis function
121 and information (for example, a customer ID, a site ID, a
machine ID, and a component serial number) regarding the
component of which the abnormality is detected on the basis of
the sensor data by the monitoring system 170 are output to the
abnormality diagnosis result table 1100 of the maintenance plan
database 161.
[0087]
Next, a process in step S1302 is performed through the
failure diagnosis function 122 of the abnormality diagnosis
unit 120. Through the failure diagnosis function 122, the
failure history database 124 is referred to with a value of the
phenomenon ID 201 extracted in the above-described process in
step S1301 as a key so that a failure corresponding to the
phenomenon detected by the monitoring system 170 is specified,
341250548 eng final
CA 02888334 2015-04-14
. _
and the failure ID 211 and the failure code 222 of the failure
are extracted. Through the failure diagnosis function 122, the
information regarding the failure extracted in the
above-described way is output to the abnormality diagnosis
5 result table 1100 of the maintenance plan database 161.
[0088]
Next, a process in step S1303 is performed through the
countermeasure extraction function 131 of the countermeasure
extraction unit 130. Through the countermeasure extraction
10 function 131, the work history database 132 is referred to with
a value of the failure ID 211 extracted through the failure
diagnosis function 122 in the process in step S1302 as a key
so that maintenance work performed on the same failure in the
past is specified, and the work code 312 thereof is extracted.
15 Through the countermeasure extraction function 131, the
extracted result is output to the countermeasure extraction
result table 1120.
[0089]
Next, a process in step S1304 is performed through the
20 countermeasure extraction function 131 of the countermeasure
extraction unit 130. Through the countermeasure extraction
function 131, the maintenance work database 133 is referred to
with the work code 312 extracted in the process in step S1303
as a key, and thus values of the work cost 408, the standard
25 work time 409, the necessary equipment 410, and the maintenance
341250548 eng_final
CA 02888334 2015-04-14
56
person's skill 411 which are necessary in the maintenance work
=
are extracted. Through the countermeasure extraction function
131, the results extracted here are output to the countermeasure
extraction result table 1120.
[0090]
Next, a process in step S1305 is performed through the
plan creation function 141 of the plan creation unit 140.
Through the plan creation function 141, equipment corresponding
to the necessary equipment 410 and a schedule of a maintenance
person having a skill indicated by the maintenance person's
skill 411, extracted in the above-described process in step
S1304, are read from the schedule database 143. Through the
plan creation function 141, the "spare date" on which the
equipment and the maintenance person can handle the maintenance
work, that is, other work schedules are not reserved, is
specified as the execution candidate date on the basis of the
schedule read here, and a period tx from the present time to
the execution candidate date is calculated. Through the plan
creation function 141, information regarding the specified
execution candidate date (corresponding to the "execution date"
in the execution candidate table 1130) and the period tx is
output to the execution candidate table 1130.
[0091]
Next, a process in step S1306 is performed through the
plan creation function 141. Through the plan creation function
341250548 eng final
CA 02888334 2015-04-14
57
= 141, it is determined whether or not the maintenance work
=
specified through the countermeasure extraction function 131
in the above-described process in step S1303 includes component
exchange work. If the maintenance work does not include the
component exchange work (S1306: No), a process in step S1307
is performed through the plan creation function 141. On the
other hand, if the maintenance work includes the component
exchange work (S1306: Yes), a process in step S1308 is performed
through the plan creation function 141.
[0092]
Next, the process in step S1307 is performed through the
plan creation function 141 of the plan creation unit 140.
Through the plan creation function 141, an operation plan is
created by referring to the execution candidate table 1130 and
the customer knowledge database 145 and is output to the
supply/operation table 1140. A specific procedure of the
operation plan creation will be described later with reference
to Fig. 14.
[0093]
On the other hand, the process in step S1308 is performed
through the plan creation function 141 of the plan creation unit
140. Through the plan creation function 141, a
supply/operation plan is created by referring to the execution
candidate table 1130, the component supply database 144, and
the customer knowledge database 145, and is output to the
341250548 eng final
CA 02888334 2015-04-14
58
supply/operation plan table 1140. A specific procedure of the
=
supply/operation plan creation will be described later with
reference to Fig. 15.
[0094]
Next, a process in step S1309 is performed by the
performance prediction unit 150. Through the lifetime
calculation function 151 of the performance prediction unit 150,
an average lifetime of a corresponding component is calculated
on the basis of the component history database 153 in relation
to the component for exchange shown in the supply/operation plan
created in the above-described process in step S1308. In
addition, through the downtime calculation function 152 of the
performance prediction unit 150, downtime of the component is
calculated on the basis of the component history database 153,
the failure history database 124, and the component running
database 154. A value of the average lifetime calculated
through the lifetime calculation function 151 and a value of
the downtime calculated through the downtime calculation
function 152 are output to the predicted result database 162
through the respective functions. Respective processes using
the lifetime calculation function 151 and the downtime
calculation function 152 will be described later with reference
to Figs. 16 to 18.
[0095]
Next, a process in step S1310 is performed through the
341250548 eng final
CA 02888334 2015-04-14
59
= periodic maintenance plan adjustment function 142 of the plan
creation unit 140. Through the periodic maintenance plan
adjustment function 142, it is determined whether or not the
execution candidate date indicated by the operation/supply plan
matches the execution schedule date of the periodic maintenance
by referring to the operation/supply plan table 1140 created
through the plan creation function 141 and the periodic
maintenance database 146. If the execution candidate date
matches the execution schedule date of the periodic maintenance
(S1310: Yes), a process in step S1311 is performed through the
periodic maintenance plan adjustment function 142. On the
other hand, if the execution candidate date does not match the
execution schedule date of the periodic maintenance (S1310: No) ,
a process in step S1312 is performed through the periodic
maintenance plan adjustment function 142.
[0096]
The process in step S1311 is performed through the plan
creation function 141 of the plan creation unit 140. Through
the plan creation function 141, the execution schedule date of
the periodic maintenance is set as the only execution candidate
date, and, if the operation/supply plan does not include the
component exchange work, the process in step S1307 is performed
so that an operation plan is created. In addition, through the
plan creation function 141, the process in step S1308 is
performed so that a supply/operation plan is created if the
341250548 eng final
CA 02888334 2015-04-14
. .
- operation/supply plan includes the component exchange work.
Through the plan creation function 141, the operation/supply
plan or the operation plan created in the above-described way
is output to the supply/operation table 1140.
5 [0097]
Next, a process in step S1312 is performed by the output
management unit 160. The output management unit 160 outputs
the maintenance plan and prediction result preserved in the
maintenance plan database 161 and the predicted result database
10 162 of the output management unit 160 in the procedures hitherto,
to the client terminal 190. The client terminal 190 displays
the maintenance plan and the prediction result on a display such
that a corresponding user can evaluate and examine the
maintenance plan.
15 [0098]
Fig. 14 illustrates an example of the operation plan
creation procedure (the process in step S1307) in the present
embodiment. The process in step S1307 is performed through the
plan creation function 141 of the plan creation unit 140. In
20 addition, the plan creation function 141 can refer to the
abnormality diagnosis result table 1100, the countermeasure
extraction result table 1120, and the execution candidate table
1130 of the maintenance plan database 161 which are output in
the processes in step S1301 to step S1305.
25 [0099]
341250548 eng final
CA 02888334 2015-04-14
61
. .
=
In this case, in a process in step S1401, through the plan
creation function 141, for example, a record (execution
candidate x) regarding an execution candidate of which the
execution date 1134 is earliest of the records of the execution
candidate table 1130 is extracted, and a value of a time period
tx from the present time to the execution date 1134 is acquired
from the extracted record and is stored in the memory 113.
[0100]
Next, in a process in step S1402, through the plan
creation function 141, the abnormality ID 1122 is specified in
the countermeasure extraction result table 1120 with a value
of the countermeasure ID 1132 indicated by the above-described
extracted record as a key, and information pieces such as a
customer ID, a site ID, a phenomenon code, phenomenon content,
a failure code, and failure content regarding a component which
is a maintenance target are specified in the abnormality
diagnosis result table 1100 with the abnormality ID 1122 as a
key. In addition, through the plan creation function 141, the
information pieces specified here are collated with the
residual lifetime table 710 of the customer knowledge database
145, and thus a value of the residual lifetime 721 of the
component is acquired. Through the plan creation function 141,
the value of the residual lifetime acquired in the
above-described way is compared with the time period tx from
the present time to the execution date 1134, and it is determined
341250548 eng final
CA 02888334 2015-04-14
62
. .
whether or not a failure will occur by execution of the
=
maintenance work.
[0101]
If a result of the above-described determination is the
residual lifetime > tx (S1402: residual lifetime > tx), through
the plan creation function 141, it is estimated that the
component will not fail by the execution date 1134, a load ratio
of the component is set to "100", and a subsequent process in
step S1405 is performed.
[0102]
On the other hand, if a result of the above-described
determination is the residual lifetime < tx (S1402: residual
lifetime < tx), it is estimated that the component will fail
by the execution date 1134 of the execution candidate x, and
a subsequent process in step S1403 is performed, through the
plan creation function 141. A case where the residual lifetime
acquired in the process in step S1402 is "0" indicates that a
function of the component is stopped due to a sudden failure.
In this case (S1402: residual lifetime=0), through the plan
creation function 141, a load ratio of the component is set to
"0" in a process in step S1404, and a subsequent process in step
S1405 is performed.
[0103]
Here, a relationship between the residual lifetime and
the execution date 1134 will be described with reference to Fig.
341250548 eng final
CA 02888334 2015-04-14
63
. .
- 19A. Fig. 19A illustrates a relationship between the residual
lifetime and the time period tx from the present time to the
execution date 1134. For example, an execution candidate 1 has
a relationship of tl < the residual lifetime, and thus it is
expected that a failure will not occur in a component by the
execution date 1134 of maintenance work. In addition, an
execution candidate 2 has a relationship of t2 > the residual
lifetime, and thus it is expected that a failure will occur in
a component by the execution date 1134 of maintenance work. In
order to perform maintenance work on the basis of the execution
candidate 2, an operation in which a load ratio of the component
is restricted after abnormality is detected is performed on the
component so that the residual lifetime is required to be
elongated.
[0104]
In a process in step S1403, through the plan creation
function 141, a load ratio at which the component will not fail
by the execution date of the maintenance work, that is, the
maximum load ratio at which the residual lifetime is longer than
tx is specified by referring to the residual lifetime table 710
of the customer knowledge database 145. For example, if the
residual lifetime is two days shorter than tx, a load ratio of
"90" at which the residual lifetime is lengthened by three days
maybe specified rather than a load ratio of "100" in the residual
lifetime table 710.
341250548 eng final
CA 02888334 2015-04-14
64
. .
. ' [0105]
In a process in step S1405, an operation loss and a work
loss are calculated through the plan creation function 141. As
described above, in a case where an operation in which a load
ratio of the component is restricted up to the execution date
of the maintenance work is required to be performed, the mining
machine 10 is not fully run during that time, and thus a
customer's profit is reduced so that an economic loss is
generated. As illustrated in Fig. 19B, this economic loss is
regarded as an operation loss. Through the plan creation
function 141, the load ratio acquired in the process in steps
S1402, S1403, or S1404 is collated with the operation loss table
700 of the customer knowledge database 145 so that a value of
the operation loss 707 is specified. In addition, through the
plan creation function 141, the specified value of the operation
loss 707 is multiplied by the above-described value of tx (the
grace period from the present time to the execution date 1134
of the maintenance work), and thus the operation loss is
calculated.
[0106]
Since the mining machine 10 is stopped during the
maintenance work, a load ratio of the component during the
maintenance work is "0". In this case, the mining machine 10
is stopped during that time, and thus a customer's profit is
reduced so as to cause an economic loss to be generated. This
341250548 eng final
CA 02888334 2015-04-14
. .
economic loss is regarded as a work loss. Through the plan
creation function 141, the standard work time 1125 extracted
from the countermeasure extraction result table 1120 is
multiplied by a value of the operation loss 707 at a load ratio
5 of "0" in the operation loss table 700 of the customer knowledge
database 145, so as to calculate the work loss.
[0107]
In a process in step S1406, through the plan creation
function 141, the load ratio, the operation loss, and the work
10 loss, corresponding to the execution candidate x, are output
to the supply/operation plan table 1140 of the maintenance plan
database 161. In addition, the process in step S1307 targets
maintenance work which does not include the component exchange
work, and, in this case, through the plan creation function 141,
15 values of the component number 1143, the recycled component
determination 1144, the warehouse 1145, the transportation
means 1146, the delivery date 1147, the component price 1148,
and the transportation cost 1149 in the supply/operation plan
table 1140 are blank, or certain determination symbols are
20 output.
[0108]
Next, in a process in step S1407, through the plan
creation function 141, it is determined whether or not there
are other execution candidates on which the processes in steps
25 S1401 to S1406 are not performed by referring to the execution
341250548 eng final
_ _
CA 02888334 2015-04-14
66
. .
= ' candidate table 1130 of the maintenance plan database 161. If
there are other execution candidates (S1407: Yes) , the process
in step S1401 is performed again through the plan creation
function 141. On the other hand, if there are no other execution
candidates (S1407: No) , the flow, that is, the process in step
S1307 is finished through the plan creation function 141.
[0109]
Fig. 15 illustrates an example of a procedure (process
in step S1308) of creating the supply/operation plan in the
present embodiment. The process in step S1308 is performed
through the plan creation function 141 of the plan creation unit
140. In addition, the plan creation function 141 can refer to
the abnormality diagnosis result table 1100, the countermeasure
extraction result table 1120, and the execution candidate table
1130 of the maintenance plan database 161 which are output in
the processes in step S1301 to step S1305.
[0110]
First, in a process in step S1501, through the plan
creation function 141, for example, an execution candidate
(execution candidate x) of which the execution date 1134 is
closest is extracted from the execution candidate table 1130,
and a time period tx from the present time to the execution date
1134 is acquired from the corresponding record and is stored
in the memory 113.
[0111]
341250548 eng final
CA 02888334 2015-04-14
67
. = Next, in a process in step S1502, through the plan
creation function 141, a value of the component serial number
1107 which is an ID of the component in which the abnormality
has detected is extracted from the phenomenon diagnosis result
table 1100 of the maintenance plan database 161. Through the
plan creation function 141, respective values of a component
number and recycled component determination are extracted by
referring to the component history database 153 with the value
of the component serial number 1107 extracted here as a key.
In addition, through the plan creation function 141, with the
respective extracted values of the component number and the
recycled component determination as keys, the component
inventory table 600 of the component supply database 144 is read,
and a value of the inventory 606 of the corresponding component
is acquired and is stored in the memory 113.
[0112]
In a process in step S1503, through the plan creation
function 141, the warehouse 605 in which an inventory is 1 or
more is selected on the basis of the value of the inventory 606
of the component supply database 144 read in the process in step
S1502.
[0113]
Next, in a process in step S1504, through the plan
creation function 141, a corresponding record is specified in
the abnormality diagnosis result table 1100 with the
341250548 _ eng _final
CA 02888334 2015-04-14
68
= abnormality ID of the execution candidate x as a key, and a value
of the site ID 1105 of a site where the mining machine 10 whose
abnormality has been detected is run is extracted from the
record. In addition, through the plan creation function 141,
the value of the site ID 1105 is collated with the customer table
730 of the customer knowledge database 145, and a value of the
site name 734 such as "siteA" is specified. Through the plan
creation function 141, with the site name (="siteA") and the
value of the warehouse 605 selected in the process in step S1503
as keys, the transportation means 613 is selected in which the
value of the transportation destination 612 in the
transportation means table 610 of the component supply database
144 is the above-described site name, and the value of the
warehouse 611 in the transportation means table 610 is the
above-described value of the warehouse 605.
[0114]
In a process in step S1505, through the plan creation
function 141, the respective values of the price of the
component extracted through the process in step S1502, the
transportation means selected through the process in step S1504,
transportation cost corresponding to the transportation means,
and the delivery date are stored in corresponding columns of
the supply/operation plan table 1140 of the maintenance plan
database 161.
[0115]
341250548 eng final
CA 02888334 2015-04-14
69
.
In a process in step S1506, through the plan creation
function 141, it is determined whether or not the component for
exchange used for the maintenance work will be delivered from
the warehouse by the execution date 1134 of the maintenance work.
In this case, through the plan creation function 141, the value
of the delivery date 1147 stored in the supply/operation plan
table 1140 is compared with the time period tx from the present
time to the execution date 1134, and if the delivery date > tx
(S1506: Yes), it is estimated that the component is scheduled
to be delivered by the execution date 1134 of the maintenance
work, and a process in step S1507 is performed. On the other
hand, if the delivery date < tx (S1506: Yes), it is estimated
that the component will not be delivered by the execution date
1134 of the maintenance work, and a process in step S1515 is
performed, through the plan creation function 141.
[0116]
Next, in the same manner as in the process in step S1402,
in the process in step S1507, through the plan creation function
141, the residual lifetime is compared with tx, and it is
determined whether or not a failure will occur in the exchange
target component by the execution date 1134 of the maintenance
work. If the residual lifetime > tx (S1507: residual lifetime
> tx), through the plan creation function 141, it is determined
that a problem does not occur by the execution date of the
maintenance work even if the component is fully run as normally
341250548 eng final
CA 02888334 2015-04-14
. .
. =
done, a load ratio of the component is set to "100" in the
supply/operation plan table 1140, and a process in step S1510
is performed.
[0117]
5 On the
other hand, if the residual lifetime < tx (S1507:
residual lifetime < tx), a process in step S1508 is performed
through the plan creation function 141. In a case where the
residual lifetime is "0" (S1507: residual lifetime=0), through
the plan creation function 141, a load ratio of the component
10 of the
supply/operation plan table 1140 is set to "0" in a process
in step S1509, and the process in step S1510 is performed.
[0118]
In same manner as in the process in step S1403, as
described above, in the process instep S1508, through the plan
15 creation
function 141, a load ratio at which the component will
not fail by the execution date 1134 of the maintenance work,
that is, the maximum load ratio at which the residual lifetime
is longer than tx is specified by referring to the residual
lifetime table 710 of the customer knowledge database 145. For
20 example, if the residual lifetime is two days shorter than tx,
a load ratio of "90" at which the residual lifetime is lengthened
by three days may be specified rather than a load ratio of "100"
in the residual lifetime table 710.
[0119]
25 In the
same manner as in the process in step S1405, as
341250548 eng final
_ _
CA 02888334 2015-04-14
71
- described above, in the process in step S1510, an operation loss
and a work loss are calculated through the plan creation
function 141. As described above, in a case where an operation
in which a load ratio of the component is restricted up to the
execution date of the maintenance work is required to be
performed, the mining machine 10 is not fully run during that
time, and thus a customer's profit is reduced so that an economic
loss is generated. Through the plan creation function 141, the
load ratio acquired in the process in steps S1507, S1508, or
S1509 is collated with the operation loss table 700 of the
customer knowledge database 145 so that a value of the operation
loss 707 is specified. In addition, through the plan creation
function 141, the specified value of the operation loss 707 is
multiplied by the above-described value of tx (the grace period
from the present time to the execution date 1134 of the
maintenance work) , and thus the operation loss is calculated.
Since the mining machine 10 is stopped during the maintenance
work, a load ratio of the component during the maintenance work
is "0". In this case, the mining machine 10 is stopped during
that time, and thus a customer' s profit is reduced so as to cause
an economic loss to be generated. This economic loss is
regarded as a work loss. Through the plan creation function
141, the standard work time 1125 extracted from the
countermeasure extraction result table 1120 is multiplied by
a value of the operation loss 707 at a load ratio of "0" in the
341250548 eng final
CA 02888334 2015-04-14
72
. .
operation loss table 700 of the customer knowledge database 145,
=
so as to calculate the work loss.
[0120]
In the same manner as in the process in step S1406, as
described above, in a process in step S1511, through the plan
creation function 141, the supply/operation plan is output to
the supply/operation table 1140 of the maintenance plan
database 161. Through the plan creation function 141, the value
of the component serial number 1107 of the corresponding
component extracted in the process in step S1502 and a recycled
component determination flag are respectively stored in the
component number 1143 and the recycled component determination
1144 of the supply/operation plan table 1140. Through the plan
creation function 141, the value of the warehouse 605 selected
in the process in step S1503 is stored in the warehouse 1145
of the supply/operation plan table 1140. In addition, through
the plan creation function 141, the transportation means
selected in the process in step S1504 is stored in the
transportation means 1146 of the supply/operation plan table
1140, and, similarly, the delivery date, the price, and the
transportation cost stored in the process in step S1505 are
respectively stored in the delivery date 1147, the component
price 1148, and the transportation cost 1149.
[0121]
Next, in a process in step S1512, through the plan
341250548 eng final
CA 02888334 2015-04-14
73
. .
creation function 141, it is determined whether or not there
is other transportation means 613 (which is not selected in the
process in step S1504) in which the respective values of the
site name (="siteA") represented in the process in step S1504
and the warehouse 605 match values of the transportation
destination 612 and the warehouse 611 in the transportation
means table 610 by referring to the transportation means table
610 of the component supply database 144. If there are other
transportation means 613 (S1512: Yes), the process in step S1504
is performed again through the plan creation function 141. On
the other hand, there are no other transportation means 613
(S1512: No), a process in step S1513 is performed through the
plan creation function 141.
[0122]
In the process in step S1513, through the plan creation
function 141, it is determined whether or not the target
component is stocked in other warehouses by referring to the
component inventory table 600 of the component supply database
144 in the same manner as in the process in step S1503, as
described above. If the target component is stocked in other
warehouses (S1513: Yes), the process in step S1503 is performed
through the plan creation function 141. On the other hand, if
the target component is not stocked in other warehouses (S1513:
No), a process in step S1514 is performed through the plan
creation function 141.
341250548 eng final
CA 02888334 2015-04-14
74
[0123]
In the process in step S1514, through the plan creation
function 141, it is determined whether or not there is a
compatible component of the component of which an inventory is
checked in the process in step S1502 by referring to the
compatible component table 620 of the component supply database
144. In a case where it is determined whether or not there is
a compatible component, through the plan creation function 141,
with values (extracted from the abnormality diagnosis result
table 1100) of the site ID 1105, the machine ID 1106, the failure
code 1110, and the like regarding the component of which an
inventory is checked in the process in step S1502 as keys, for
example, a record is searched for in the failure history
database 124, and the type name 215, the part code 217, and the
part name 218 of the mining machine 10 are specified from the
record. Through the plan creation function 141, the compatible
component table 620 is searched with the respective values of
the type name 215, the part code 217, and the part name 218
specified here as keys, and it is determined whether or not there
is a component having the same values of the type name 621, the
part code 622, and the part name 623 but having a component number
which is different from the component number of the component
of which an inventory is checked in the process in step S1502,
that is, a compatible component. In this process in step S1514,
if it is determined that there is a compatible component (S1514:
341250548 eng final
CA 02888334 2015-04-14
- Yes), the process in step S1502 is performed again through the
plan creation function 141. On the other hand, if it is
determined that there is not a compatible component (S1514: No),
a process in step S1515 is performed through the plan creation
5 function 141.
[0124]
Next, in the same manner as in the process in step S1406,
in the process in step S1515, through the plan creation function
141, it is determined whether or not there are other execution
10 candidates on which the processes are not performed by referring
to the execution candidate table 1130 of the maintenance plan
database 161. If there are other execution candidates on which
the processes are not performed (S1515: Yes), the process in
step S1501 is performed again through the plan creation function
15 141. On the other hand, if there are no other execution
candidates on which the processes are not performed (S1515: No) ,
the flow, that is, the process in step S1308 is finished through
the plan creation function 141.
[0125]
20 Next, Figs. 16 to 18 illustrate an example of the
lifetime/downtime simulation execution procedure (process in
step S1309) in the present embodiment. Lifetime/downtime
simulation processes include a lifetime simulation S1309(a)
illustrated in Fig. 16, a downtime simulation S1309(b)
25 illustrated in Fig. 17, and a downtime simulation 1309(c)
341250548 eng final
CA 02888334 2015-04-14
76
. .
= illustrated in Fig. 18, but the simulation procedures are
independent from each other and may thus be performed from any
procedure. The lifetime prediction simulation illustrated in
Fig. 16 is executed through the lifetime calculation function
151 of the performance prediction unit 150, and the downtime
simulation illustrated in Figs. 17 and 18 are executed through
the downtime calculation function 152. The lifetime
calculation function 151 and the downtime calculation function
152 can refer to the maintenance plan database 161 which is
output in the processes in steps S1301 to S1308.
[0126]
Fig. 16 illustrates an example of a procedure of
performing the lifetime simulation in the present embodiment.
In a flow of the lifetime simulation, through the lifetime
calculation function 151, lifetime of a component which was used
and exchanged in the past is calculated by referring to the
component history database 153. In this case, in a process in
step S1601, the component history database 153 is read through
the lifetime calculation function 151.
[0127]
In a process in step S1602, through the lifetime
calculation function 151, respective values of the component
number 1143 and the recycled component determination 1144 of
the component for exchange used for the maintenance work are
extracted from the supply/operation plan table 1140 of the
341250548_eng final
CA 02888334 2015-04-14
77
maintenance plan database 161, the component history database
153 is searched with the values as keys, and a record regarding
a corresponding component in which the respective values of the
component number 1143 and the recycled component determination
1144 match values of the component number 9043 and the recycled
component determination 905 is specified. Through the
lifetime calculation function 151, a value of the situation flag
910 is read from each extracted record, a record of a component
in which the value thereof is "exchanged" is specified, and the
data is stored in the memory 113.
[0128]
Next, in a process in step S1603, through the lifetime
calculation function 151, a difference between values of the
attachment date and time 911 and the detachment date and time
912 in the data regarding each component obtained in the process
in step S1602 is calculated as lifetime of the corresponding
component. Through the lifetime calculation function 151,
determination in a process in step S1604 is performed so that
the lifetime calculation process, that is, the process in step
S1603 is performed on all data items extracted in the process
in step S1602, and thus the above-described lifetime
calculation is performed on all the data items extracted in the
process in step S1602.
[0129]
In a process in step S1605, through the lifetime
341250548 eng final
CA 02888334 2015-04-14
78
= .
= calculation function 151, an average value of values of the
lifetime calculated with respect to the respective data items
in the process in step S1603 is calculated, and the average value
is output as a value of the average lifetime 1208 in the predicted
result database 162. In addition, through the lifetime
calculation function 151, the number of data items specified
in the process in step S1603 is output to the predicted result
database 162 as the number of samples 1211.
[0130]
In a process in step S1606, through the lifetime
calculation function 151, it is determined whether or not a plan
using another component different from the component which is
specified by each set of values of the component number 1143
and the recycled component determination 1144 of the component
for exchange used for the maintenance work, extracted in the
process in step S1602, is stored in the supply/operation table
1140 of the maintenance plan database 161. If there is a plan
using another component (S1606: Yes) , through the lifetime
calculation function 151, the component is set as a processing
target, and the processes in step S1602 and the subsequent steps
are performed again. On the other hand, if there is no plan
using another component (S1606: No) , through the lifetime
calculation function 151, this flow, that is, the procedure
S1309 (a) is finished.
[0131]
341250548 eng final
CA 02888334 2015-04-14
79
= .
-
Fig. 17 illustrates an example of a procedure of
performing a downtime simulation on the basis of the failure
history database 124 and the component history database 153 in
the present embodiment. In this case, in the downtime
simulation, through the downtime calculation function 152,
downtime of a component which was used and exchanged in the past
is calculated by referring to the failure history database 124
and the component history database 153.
[0132]
First, in processes in steps S1701 and S1702, in the same
manner as in the processes in steps S1601 and S1602, through
the downtime calculation function 152, the component history
database 153 is read, respective values of the component number
1143 and the recycled component determination 1144 of the
component for exchange used for the maintenance work are
extracted from the supply/operation plan table 1140 of the
maintenance plan database 161, the component history database
153 is searched with the values as keys, and a record regarding
a corresponding component in which the respective values of the
component number 1143 and the recycled component determination
1144 match values of the component number 9043 and the recycled
component determination 905 is specified. Through the
downtime calculation function 152, a value of the situation flag
910 is read from each record extracted here, a record of a
component in which the value thereof is "exchanged" is specified,
341250548 eng final
CA 02888334 2015-04-14
. .
and the data is stored in the memory 113.
[0133]
In a process in step S1703, through the downtime
calculation function 152, a component serial number is acquired
5 from the
data obtained in the process in step s1702. In addition,
in a process in step S1704, through the downtime calculation
function 152, the failure history database 124 is referred to
with the acquired component serial number as a key.
[0134]
10 In a
process in step S1705, through the downtime
calculation function 152 referring to the failure history
database 124, it is determined whether or not there is failure
history in a component indicated by the component serial number.
If there is the failure history (S1705: Yes), a process instep
15 S1706 is
performed through the downtime calculation function
152. On the other hand, if there is no failure history (S1705:
No), a process in step S1708 is performed through the downtime
calculation function 152.
[0135]
20 Next, in
the process in step S1706, through the downtime
calculation function 152, the work history database 132 is
referred to with the failure ID 211 of the failure history
database 124 as a key, and a difference between the handling
start date and time 303 and the handling end date and time 304
25 of
corresponding work is calculated as downtime corresponding
341250548 eng final
CA 02888334 2015-04-14
81
. .
to the failure ID 211. In addition, in the process in step s1707,
through the downtime calculation function 152, it is determined
whether or not downtime is calculated with respect to all
components determined to fail in the process in step S1705. If
there is a failure in relation to which downtime is not
determined (S1707: No), through the downtime calculation
function 152, the process in step S1706 is repeatedly performed,
and if downtime is calculated in relation to all failures
(S1707: Yes), a process in step S1707 is performed.
[0136]
In a process in step S1708, through the downtime
calculation function 152, it is determined whether or not the
last row of the data items extracted from the component history
database 153 in the process in step S1702 comes. If the last
row comes (S1708: Yes), through the downtime calculation
function 152, a process in step S1709 is performed. On the other
hand, if there is remaining data (S1708: No), through the
downtime calculation function 152, the processes in step S1703
and the subsequent steps are performed again, and downtime of
a corresponding component is calculated.
[0137]
In the process in step S1709, through the downtime
calculation function 152, an average value of an amount of
downtime calculated in the process in step S1706 is calculated,
and is stored as a value of the history base average DT 1209
341250548 eng final
_ _
CA 02888334 2015-04-14
82
= of the performance prediction database 162.
[0138]
In a process in step S1710, through the downtime
calculation function 152, in the same manner as in the process
in step S1606, it is determined whether or not there is a plan
of using another component in the supply/operation table 1140
of the maintenance plan database 161. If there is a plan using
another component (S1710: Yes), through the downtime
calculation function 152, the component is set as a processing
target, and the processes in step S1702 and the subsequent steps
are performed again. On the other hand, if there is no plan
using another component (S1710: No), through the downtime
calculation function 152, this flow, that is, the procedure
S1309(b) is finished.
[0139]
Fig. 18 illustrates an example of a procedure of
performing the downtime simulation in the present embodiment.
In this case, in the downtime simulation, through the through
the downtime calculation function 152, downtime of a component
which was used and exchanged in the past is calculated by
referring to the failure history database 124, the component
history database 153, and the component running database 154.
Fundamental processes in the execution procedure (S1309(c))
described here are the same as the above-described processes
in the procedure S1309(b). Therefore, herein, processes in
341250548 eng final
CA 02888334 2015-04-14
83
. .
steps S1804 to S1807 which are different from the procedure
S1309(b) and in which downtime is calculated, and a process in
step S1809 for performing outputting will be described.
[0140]
In this case, in a process in step S1804, through the
downtime calculation function 152, in the same manner as in the
processes in steps S1701 to S1703, data of the component running
database 154 is narrowed down by using the acquired component
serial number.
[0141]
In a process in step S1805, through the downtime
calculation function 152, a value of the period 1013 is referred
to in the running result table 1010 of the component running
database 154 acquired in the above-described way, and the unit
time for determination is calculated (the unit time is one hour
in the example of Fig. 10B). In addition, through the downtime
calculation function 152, the determination value 1005 and the
determination condition 1006 are referred to in the running
determination table 1000 of the component running database 154,
and a record in which the average value 1014 of the running result
table 1010 is smaller than a value of the determination value
1005 is specified as the component being "currently stopped".
Through the downtime calculation function 152, values of the
unit time are integrated by the number of records specified as
"currently stopped", and time periods determined as being
341250548 eng final
CA 02888334 2015-04-14
84
"currently stopped" are integrated.
[0142]
In a process in step S1806, through the downtime
calculation function 152, the detachment date and time 912 of
the component history database 153 is compared with a value of
the period 1013 of the record (the record of the running result
table 1010) which is a target of the integration process instep
S1805, and, if the date indicated by the period 1013 reaches
the detachment date and time 912 (S1806: Yes), the integration
process in step S1805 is finished, and a process in step S1807
is performed. On the other hand, if the date indicated by the
period 1013 does not reach the detachment date and time 912
(S1806: No), the process is returned to the process in step S1805
through the downtime calculation function 152.
[0143]
In the process in step S1807, through the downtime
calculation function 152, an amount of time integrated hitherto,
that is, downtime is stored in the memory 113 as running base
downtime of the component. In addition, through the downtime
calculation function 152, the processes up to step S1807 are
repeatedly performed on all data items obtained in the process
in step S1802 (step S1808).
[0144]
In a process in step S1809, through the downtime
calculation function 152, an average of an amount of downtime
341250548 eng final
CA 02888334 2015-04-14
obtained for the respective data items extracted in the process
in step S1802 is calculated and is stored as the running base
average DT 1209 in the predicted result database 162.
[0145]
5 Figs. 20 to
22 illustrate an output screen example in the
present embodiment. Regarding such an output screen, for
example, the output management unit 160 extracts necessary data
for each kind of screen from the data stored in the maintenance
plan database 161 and the predicted result database 162 in
10 response to
a request from the client terminal 190, sets the
data in a format (held by the output management unit 160) of
the screen so as to generate the screen, and outputs the screen
to the client terminal 190. Of course, the output management
unit 160 may output data for a screen format to the client
15 terminal
190 and may receive a customizing operation for forming
a screen from a user, as necessary.
[0146]
Fig. 20 illustrates a screen 2000 which displays a
maintenance plan candidate list. On this screen 2000,
20 respective records are listed in an ascending order or a
descending order of total cost, average lifetime, history base
average DT, or running base average DT. In addition, the screen
2000 includes a radio button 2001 for designating any one of
the total cost, the average lifetime, the history base average
25 DT, and the running base average DT as an rearrangement
341250548 eng final
CA 02888334 2015-04-14
86
criterion so that a user rearranges the records on the basis
of this listing criterion. The user can evaluate the
maintenance plan candidates by pressing the radio button 2001.
In addition, an item of user definition may be included so that
a value of each column is computed by using a numerical
expression.
[0147]
Fig. 21 illustrates an example of a display screen 2100
of details and an operation of a supply/operation plan regarding
the maintenance plan candidate displayed on the screen 2000
illustrated in Fig. 20. Regarding the screen 2100, the output
management unit 160 extracts data necessary in the screen from
the data stored in the maintenance plan database 161 and the
predicted result database 162 when a request for specific
display of a certain candidate is received from the client
terminal 190 on the screen 2000, sets the data in a format of
the screen so as to generate the screen, and outputs the screen
to the client terminal 190. The screen 2100 visually displays
values of a plan ID, the execution date , a machine ID, a component
number, a warehouse, transportation means, the delivery date,
a component price, a transportation cost, recycled component
determination indicating whether or not a component for
exchange used for maintenance work is a recycled component, a
load ratio of the component up to the maintenance work, time
t up to the execution date of the maintenance work, maintenance
341250548 eng final
CA 02888334 2015-04-14
87
= work time, a residual lifetime, an operation loss, and a work
loss regarding the target supply/operation plan, thereby
supporting a user's understanding of the maintenance work.
[0148]
Fig. 22 illustrates a screen 2200 which shows cost
distribution related to the maintenance work. The screen 2200
may be used, for example, in a case or the like where a share
of maintenance cost is defined between a maintenance service
provider and a customer operating the mining machine 10 on a
maintenance contract. For example, in such a contract in which
a cost born by the customer are limited to components for
exchange, and other maintenance costs are born by the
maintenance service provider, a component price and a total cost
excluding the component price may be compared and examined.
Therefore, the screen 2200 includes a radio button 2201 for
designating any one of a total cost, a component price, a
transportation cost, an operation loss, a work cost, a work loss,
and user definition as a rearrangement criterion so that the
respective records are rearranged in an ascending order or a
descending order of the total cost, the component price, the
transportation cost, the operation loss, the work cost, the work
loss, and the user definition. The user can evaluate the
maintenance plan candidates through comparison between costs
by pressing the radio button 2201. In addition, an item of user
definition may be included so that a value of each column is
341250548 eng final
CA 02888334 2015-04-14
88
computed by using a numerical expression.
[0149]
Hereinafter, a brief description will be made of Example
of outputting a maintenance plan candidate estimated to be
optimum to a customer with reference to Figs. 23 to 29. Fig.
23 is a diagram illustrating a configuration example of an
output management unit 2300 which proposes a maintenance plan
candidate estimated to be the optimum to a customer in the
present example. The output management unit 2300 includes a
maintenance plan evaluation function 2301, a customer policy
estimation function 2302, a maintenance plan database 2303, a
predicted result database 2304, and a plan evaluation database
2305 (tenth database). The maintenance plan evaluation
function 2301 is used to rank a plurality of maintenance plans
on the basis of a plurality of evaluation indexes and customer
policy. The customer policy estimation function 2302
estimates a tendency of the customer to select what type of a
maintenance plan. Herein, a tendency of the customer is
referred to as a customer policy . The maintenance plan database
2303 and the predicted result database 2304 respectively have
the same structures as those of the maintenance plan database
161 and the predicted result database 162. The plan evaluation
database 2305 includes a maintenance plan evaluation table 2400
which stores results of maintenance plan evaluation performed
by using the maintenance plan evaluation function 2301 and a
341250548 eng final
CA 02888334 2015-04-14
89
maintenance selection history table 2410 referred to by the
customer policy estimation function 2302.
[0150]
Hereinafter, as an example, a description will be made
of a process in which a sum total of the component price 1148,
the transportation cost 1149, the operation loss 1151, and the
work loss 1152 is set as a maintenance cost, and a maintenance
plan is evaluated by using the maintenance cost and the running
base average DT 1209 as evaluation indexes.
[0151]
The maintenance plan evaluation table 2400 of Fig. 24
stores a plan ID 2401, a maintenance cost 2402 and a running
base average DT 2403 which are evaluation indexes, and a score
2412, a score A 2405, and a score B 2406 which are calculated
through the maintenance plan evaluation function 2301. The
score A 2405 is a score obtained by evaluating a maintenance
plan candidate through trade-off analysis using a Pareto
optimal solution set; the score B 2406 is a score obtained by
evaluating a maintenance plan candidate with a degree of
coincidence with a customer policy; and the score 2404 is a
comprehensive score of a maintenance plan calculated from the
score A 2405 and the score B 2406. Calculation expressions of
the score A, the score B, and the comprehensive score will be
described later.
[0152]
341250548 eng final
CA 02888334 2015-04-14
The maintenance selection history table 2410 of Fig. 25
stores an abnormality ID 2411 occurred in the past, a
countermeasure ID 2412 performed on the abnormality, a plan ID
2413 of a maintenance plan candidate displayed to the customer
5 when the abnormality occurred, a maintenance cost 2402 and
running base average DT 2415 which are evaluation indexes of
the maintenance plan candidate, and execution history 2416
selected by the customer. In the maintenance selection history
table 2410, abnormality in the past, a countermeasure, a
10 maintenance plan candidate, and a maintenance plan selected by
the customer are correlated with each other.
[0153]
With reference to Fig. 26, a description will be made of
a procedure S2500 in which, among maintenance plan candidates,
15 a maintenance plan which is the optimum to the customer is
estimated and is proposed. In step S2501, through the
maintenance plan evaluation function 2301, the maintenance cost,
the average lifetime 1207, and the running base average DT 1209
are extracted as evaluation indexes from the supply/operation
20 table 1140 of the maintenance plan database 2303 and the
predicted result database 2304. Smaller maintenance cost and
running base average DT 1209 are preferably used and thus
inverse numbers thereof are taken. Next, each evaluation index
is normalized so that the maximum value thereof becomes 1. The
25 best value of each index becomes 1 through this operation.
341250548 eng final
CA 02888334 2015-04-14
91
[0154]
In step S2502, through the maintenance plan evaluation
function 2301, a Pareto optimal solution set is obtained from
a plurality of maintenance plan candidates by using the three
normalized evaluation indexes. The reference numeral 2601 of
Fig. 27 indicates an example in which a Pareto optimal solution
set is obtained by using two evaluation axes including the
maintenance cost and the running base average DT 1209.
[0155]
In step S2503, through the customer policy estimation
function 2302, maintenance plan candidates recommended for a
set of abnormality occurred in the past, a failure, and work,
and a maintenance plan selected by the customer among the
maintenance plan candidates are read from the customer policy
estimation function 2302, and respective values of the
normalized evaluation indexes are extracted from the
maintenance selection history table 2410.
In step S2504, through the customer policy estimation
function 2302, a customer policy is estimated on the basis of
the respective values of the evaluation indexes of the
maintenance plan selected by the customer in the past. As an
example, the reference numeral 2602 of Fig. 28 indicates a
result in which a customer policy on two evaluation axes
including the maintenance cost and the running base average DT
is estimated by using a least square method.
341250548 eng final
CA 02888334 2015-04-14
92
[0156]
In a process in step S2505, through the maintenance plan
evaluation function 2301, in relation to each maintenance plan
candidate, the score A is obtained on the basis of the Pareto
optimal solution set, the score B is obtained on the basis of
the estimated customer policy, a score is given to each
maintenance plan candidate by using the score A and the score
B, and a result thereof is stored in the maintenance plan
evaluation table 2400.
[0157]
For example, as indicated by the reference numeral 2603
of Fig. 29, when a distance from the Pareto optimal solution
set is denoted by L1, and a distance from the customer policy
is denoted by L2, the maximum value of L1 and L2 is Ai2, and the
minimum value thereof is O. Here, the maximum score of 10 is
given to a maintenance plan candidate which matches the Pareto
optimal solution set or the estimated customer policy, and the
minimum value of 0 is given to a maintenance plan candidate which
is most distant from the Pareto optimal solution set or the
estimated customer policy. Therefore, the score A is
calculated by 10x(42-L1)/AI2, and the score B is calculated by
10x(-\/2-L2)/Al2. In addition, if the comprehensive score is
calculated by using product of the score A and the score B,
comprehensive evaluation can be made as the maximum score of
100 and the minimum score of O. Scores of each maintenance plan
341250548 eng final
CA 02888334 2015-04-14
93
candidate calculated by using the procedure are indicated as
the score 2404, the score A 2405, and the score B 2406 in Fig.
24.
[0158]
The plan IDs="MP-001" and "MP-008" have the same score
in terms of the score A evaluated on the basis of the Pareto
optimal solution set, and thus ranking cannot be given, but the
score B based on the customer policy is added to the evaluation,
and thus the plan ID="MP-001" is estimated to be prioritized
by the customer. In addition, in evaluation using only the
score A, "MP-002" which is ranked lower than "MP-001" and
"MP-008" is estimated to be the most prioritized maintenance
plan in the customer.
[0159]
In a process in step S2506, the output management unit
2300 outputs the maintenance plans, the predicted results, and
the maintenance plan evaluation results stored in the
maintenance plan database 2303, the predicted result database
2304, and the plan evaluation database 2305 to the user in the
order of the score 2404, and waits for the user's selection.
[0160]
In a process in step S2507, through the customer policy
estimation function 2302, the user's selection is stored in the
maintenance selection history table 2410.
[0161]
341250548 eng final
CA 02888334 2015-04-14
94
In the present example, the estimated customer policy is
calculated by normalizing values of the maintenance cost and
the running base average DT used as evaluation indexes (the
reference numeral 2602 of Fig. 28). This is because a
maintenance cost or running base average DT is assumed to
greatly differ depending on a component used for maintenance
work or performed work, but the maintenance cost or the running
base average DT is in the same order in a similar component or
work. In this case, customer policy may be estimated by using
values of the evaluation indexes as they are without
normalization. ,In the present example, a description has been
made of a procedure of estimating policy on the basis of history
information of a single customer, but, for example, in a case
where similarity in policy is admitted for each country or each
area, history information may be collected and evaluated for
each country or each area. In addition, in a case where
different tendencies are shown for each part such as an engine
or a pump even in the same customer, history information may
be subdivided and evaluated for each part.
[0162]
As mentioned above, the preferred embodiment and the like
for implementing the present invention have been described in
detail, but the present invention is not limited thereto, and
may have various modifications within the scope without
departing from the spirit thereof.
341250548 eng final
CA 02888334 2015-04-14
[0163]
According to the present embodiment, a plurality of kinds
of components such as an old version component and a recycled
component can be taken into consideration in components having
5 the same function without uniformly treating exchange
components, and these various kinds of components can be
reflected in maintenance plan developing of a work machine. In
addition, since abnormality and a failure are estimated on the
basis of a phenomenon occurring in a work machine, and
10 maintenance work can be specified according thereto, failures
can be estimated so as to be suitable for various situations,
and accurate maintenance handling can be specified. Further,
in a large machine such as a mining machine, it is possible to
support developing of a plurality of patterns of maintenance
15 plans by totally taking into consideration the delivery date,
a transportation cost, a load ratio, and an economic loss
according to the load ratio while taking into consideration an
old version component or a recycled component in relation to
component supply which is an important factor to be examined
20 in terms of a cost or time required in maintenance work.
According to the maintenance-plan-developing support
technique of the present embodiment, when abnormality or a
failure is detected in a work machine, it is possible to support
maintenance plan developing business by taking into
25
consideration an old version component or a recycled component
341250548 eng final
CA 02888334 2015-04-14
96
and a supply plan thereof and by providing the time and a
countermeasure to a user along with evaluation thereof.
[0164]
Therefore, according to the present embodiment, it is
possible to efficiently draft an effective maintenance plan
without depending on a maintenance person's skill or the like.
[0165]
Through the disclosure of the present specification, at
least following facts will be apparent. In other words, in the
maintenance-plan-developing support system of the present
embodiment, the storage device may further include a fifth
database that holds information pieces regarding a load
ratio-based residual lifetime during a failure and an economic
loss in a work machine user due to a load ratio reduction in
correlation with each other, and the calculation device may
further perform a process of collating information regarding
a load ratio of a component of the work machine or the phenomenon
occurrence location, included in the information regarding the
phenomenon of the work machine with the fifth database so as
to estimate residual lifetime of the component of the work
machine or the phenomenon occurrence location, setting a load
ratio which is reduced according to an extent of the residual
lifetime being lower than the grace time from the present time
to the maintenance execution candidate date as a load ratio of
the work machine, specifying an economic loss at the load ratio
341250548 eng final
CA 02888334 2015-04-14
97
in the fifth database, and outputting the maintenance plan
information including information regarding economic losses at
the reduced load ratio and the corresponding load ratio to the
output device. With this configuration, it is possible to
specify a load ratio to be reduced to an extent in which a failure
component is continuously run up to the maintenance execution
date and to present an economic loss of a customer side when
the component is run at the load ratio, to a user, and the user
side easily gives consideration to the customer side in terms
of business continuity and economy which are important factors
when deciding a maintenance plan.
[0166]
In addition, in the maintenance-plan-developing support
system of the present embodiment, the storage device may further
include a sixth database that stores information pieces
regarding attachment and detachment of each component, or an
old version or recycled component thereof to and from the work
machine, and the calculation device may further perform a
process of specifying history of attachment and detachment of
the same type of component, or the same type of old version or
recycled component thereof as the component, or the old version
or recycled component thereof used for the maintenance work
indicated by the maintenance plan information in the sixth
database, calculating a period of time between the specified
attachment and detachment as a lifetime, and outputting the
341250548 eng final
CA 02888334 2015-04-14
98
maintenance plan information including information regarding
the lifetime to the output device. With this configuration,
since a lifetime of a component for exchanged, employed in a
maintenance plan is presented to the user, there is an effect
in which, for example, the user side easily drafts a maintenance
plan in which balance between a component cost and a lifetime
are taken into consideration.
[0167]
Further, in the maintenance-plan-developing support
system of the present embodiment, the calculation device may
further perform a process of specifying the presence or absence
of information regarding a failure of the same type of component,
or the same type of old version or recycled component thereof
as the component, or the old version or recycled component
thereof used for the maintenance work indicated by the
maintenance plan information in the first database, specifying
information regarding maintenance work performed on the failure
if there is the information regarding the failure in the first
database, calculating a period of time from work start to work
finish indicated by the information regarding the maintenance
work as downtime, and outputting the maintenance plan
information including information regarding the downtime to the
output device. . With this configuration, since downtime
expected to occur in a component for exchanged, employed in a
maintenance plan is presented to the user on the basis of
341250548 eng final
CA 02888334 2015-04-14
99
maintenance work in the past, there is an effect in which, for
example, the user side easily drafts a maintenance plan in which
balance between a component cost and downtime are taken into
consideration.
[0168]
Still further, in the maintenance-plan-developing
support system of the present embodiment, the storage device
may further include a seventh database that stores a measurement
value regarding a behavior of a component, from a sensor
provided at the component of a work machine; and an eighth
database that stores a condition of a measurement value from
the sensor, for determining whether or not the component of the
work machine is run, and the calculation device may further
perform a process of specifying information regarding a
measurement value of the same type of component, or the same
type of old version or recycled component thereof as the
component, or the old version or recycled component thereof used
for the maintenance work indicated by the maintenance plan
information in the seventh database, collating information
regarding the specified measurement value with the eighth
database, calculating a running stop period of the component,
or the old version or recycled component thereof as downtime,
and of outputting the maintenance plan information including
information regarding the downtime to the output device. With
this configuration, since downtime expected to occur in a
341250548 eng final
CA 02888334 2015-04-14
100
component for exchanged, employed in a maintenance plan is
presented to the user on the basis of running results in the
past, originated from sensor data, there is an effect in which,
for example, the user side easily drafts a maintenance plan in
which balance between a component cost and downtime are taken
into consideration.
[0169]
Furthermore, in the maintenance-plan-developing support
system of the present embodiment, the storage device may further
include a ninth database that stores a schedule of periodic
maintenance which is planned to be performed on a work machine,
and the calculation device may further perform a process of
determining whether or not the schedule of periodic maintenance
is included within a period to the maintenance execution
candidate date indicated by the maintenance plan information
in the ninth database, replacing the maintenance execution
candidate date with the periodic maintenance date if the
schedule of the periodic maintenance is included within the
period, and generating the maintenance plan information again.
With this configuration, it is possible to effectively utilize
an opportunity of periodic maintenance in an irregular failure
occurrence event and to efficiently draft a maintenance plan
without wasting the opportunity of the periodic maintenance
planned in advance.
Reference Signs List
341250548 eng final
CA 02888334 2015-04-14
101
[0170]
MINING MACHINE (WORK MACHINE)
11 SENSOR
100 MAINTENANCE-PLAN-DEVELOPING SUPPORT SYSTEM
5 111 I/0 (OUTPUT DEVICE)
112 COMMUNICATION DEVICE
113 MEMORY
114 CPU (CALCULATION DEVICE)
115 STORAGE DEVICE
10 120 ABNORMALITY DIAGNOSIS UNIT
123 PHENOMENON HISTORY DATABASE (FIRST DATABASE)
124 FAILURE HISTORY DATABASE (FIRST DATABASE)
130 COUNTERMEASURE EXTRACTION UNIT
132 WORK HISTORY DATABASE (FIRST DATABASE)
133 MAINTENANCE WORK DATABASE (SECOND DATABASE)
140 PLAN CREATION UNIT
143 SCHEDULE DATABASE (THIRD DATABASE)
144 COMPONENT SUPPLY DATABASE (FOURTH DATABASE)
145 CUSTOMER KNOWLEDGE DATABASE (FIFTH DATABASE)
146 PERIODIC MAINTENANCE DATABASE (NINTH DATABASE)
150 PERFORMANCE PREDICTION UNIT
153 COMPONENT HISTORY DATABASE (SIXTH DATABASE)
154 COMPONENT RUNNING DATABASE
1000 RUNNING DETERMINATION TABLE (EIGHTH DATABASE)
1010 RUNNING RESULT TABLE (SEVENTH DATABASE)
341250548 eng final
CA 02888334 2015-04-14
102
160 OUTPUT MANAGEMENT UNIT
161 MAINTENANCE PLAN DATABASE
162 PREDICTED RESULT DATABASE
170 MONITORING SYSTEM
180 NETWORK
190 CLIENT TERMINAL
341250548 eng final
