TWI882368B - Diagnosis method and diagnosis system for position transducer - Google Patents

Abstract

A diagnosis method and a diagnosis system for a position transducer are provided. The diagnosis system includes a controller, a position transducer and a power mechanism. The diagnosis method includes configuring the controller to: generate a control command corresponding to a target operation for the power mechanism to drive the position transducer, wherein a command value data set is generated according to the control command; receive a feedback signal generated by the position transducer, and process the feedback signal to generated a feedback value data set corresponding to the command value data set; compare the command value data set with the corresponding feedback value data to generate a plurality of comparison results; and count the comparison results obtained within a predetermined period of time to generate a diagnostic result, and determine a deterioration state and an abnormal state of the position transducer according to the diagnostic result.

Description

Diagnostic method and diagnostic system for resistance ruler

The present invention relates to a diagnosis method and a diagnosis system for a resistance ruler, and in particular to a diagnosis method and a diagnosis system for diagnosing whether a resistance ruler is deteriorated or abnormal.

Injection molding machines are a common type of plastic product manufacturing machine. In the production process of plastic products, a resistive ruler is often installed on the injection molding machine as a feedback signal source to indicate the position of the mold, so as to control the mold to move to different positions and adjust the mold movement speed accordingly.

However, after a long period of repeated operation, the resistance ruler will deteriorate due to the use environment (such as temperature, humidity), operation method (such as different speeds) and use time, resulting in the degradation of the components in the resistance ruler, which will cause the feedback mechanism to slow down and become less stable. Since the time of the above-mentioned failure is not fixed, it is often necessary to frequently stop production and maintain the resistance ruler without knowing whether the injection molding machine has a failure, in order to prevent sudden failures.

Furthermore, when faced with sudden failures, manpower is often required to be urgently dispatched to troubleshoot the failures, which not only consumes time and manpower costs, but also delays production schedules due to the occurrence of failures, thereby reducing the production capacity of the injection molding machine and reducing the profits of the manufacturer.

On the other hand, unmanned production lines often use manufacturing equipment that uses a resistive scale to implement position feedback. For example, in the product manufacturing process, the action of picking up objects is often performed by a robot arm. Therefore, when the resistive scale installed on the product manufacturing equipment has an abnormal position feedback, the robot arm will not be able to pick up the object normally, causing the unmanned production line to stop production. In this way, the utilization rate of the product manufacturing equipment will be reduced, and further affect its production capacity and the profit of the producer.

Therefore, how to respond to and/or predict the degradation or abnormality of the resistance ruler in real time to ensure the productivity of the equipment equipped with the resistance ruler has become one of the important issues that this technical field wants to solve.

The technical problem to be solved by the present invention is to provide a diagnosis method and a diagnosis system for a resistance ruler in view of the shortcomings of the prior art, so as to immediately respond to and/or predict the degradation or abnormality of the resistance ruler and improve the utilization rate of the manufacturing equipment.

In order to solve the above technical problems, one embodiment of the present invention is to provide a diagnostic method for a resistance ruler. The diagnostic method is applicable to a diagnostic system including a controller, a resistance ruler to be tested and a power mechanism. The resistance ruler to be tested is electrically connected to the controller, and the power mechanism is coupled to the resistance ruler to be tested. The diagnostic method includes configuring the controller to execute the following steps: generating a control command corresponding to a target operation to control the power mechanism to drive the resistance ruler to be tested. , wherein a command value data set is generated according to a control command; a feedback signal generated by the resistance ruler to be tested is received and processed to generate a feedback value data set corresponding to the command value data set; the command value data set is compared with the corresponding feedback value data set to generate a plurality of comparison results; and a plurality of comparison results obtained within a predetermined time period are statistically analyzed to generate a diagnosis result, wherein a degradation state and an abnormal state of the resistance ruler to be tested are defined according to the diagnosis result.

In order to solve the above technical problems, another embodiment of the present invention is to provide a diagnostic system, which includes a controller, a resistance gauge to be measured and a power mechanism. The resistance gauge to be measured is electrically connected to the controller, and the power mechanism is coupled to the resistance gauge to be measured. The controller is configured to perform the following steps: generate a control command corresponding to a target operation to control a power mechanism to drive the resistance scale to be tested, wherein a command value data set is generated according to the control command; a feedback signal generated by the resistance scale to be tested is received and processed to generate a feedback value data set corresponding to the command value data set; the command value data set is compared with the corresponding feedback value data set to generate a plurality of comparison results; and a plurality of comparison results obtained within a predetermined time period are statistically analyzed to generate a diagnosis result, wherein a degradation state and an abnormal state of the resistance scale to be tested are defined according to the diagnosis result.

To further understand the features and technical contents of the present invention, please refer to the following detailed description and drawings of the present invention. However, the drawings provided are only used for reference and description and are not used to limit the present invention.

The following is an explanation of the implementation of the "diagnostic method and diagnostic system for a resistance ruler" disclosed in the present invention through specific concrete embodiments. Technical personnel in this field can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and the details in this specification can also be modified and changed in various ways based on different viewpoints and applications without departing from the concept of the present invention. In addition, the drawings of the present invention are only for simple schematic illustrations and are not depicted according to actual sizes. Please note in advance. The following implementation will further explain the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of protection of the present invention. In addition, the term "or" used herein may include any one or a combination of multiple of the associated listed items as the case may be.

FIG1 is a schematic diagram of a diagnostic system according to an embodiment of the present invention. Referring to FIG1 , an embodiment of the present invention provides a diagnostic system 100 for a resistance ruler, wherein the diagnostic system 100 includes a controller 1, a resistance ruler to be tested 2, and a power mechanism 3. The resistance ruler to be tested 2 is electrically connected to the controller 1, the power mechanism 3 is coupled to the resistance ruler to be tested 2, and the controller 1 is electrically connected to the power mechanism 3.

In this embodiment, the controller 1 may include, for example, a storage unit and a processor unit, wherein the storage unit may be, for example, a memory, and the processor unit may be, for example, a microprocessor. In some embodiments, the controller 1 may be implemented in the form of a general-purpose computer, which includes a microprocessor capable of executing computer-readable instructions/software, other suitable computer processors, or a central processing unit (CPU). In addition, when the controller 1 is implemented in the form of a general-purpose computer, a built-in storage unit (e.g., memory) may be used to store data, a plurality of computer-readable instructions, software, control commands, and feedback data corresponding to the control commands.

The resistance ruler 2 to be measured may be, for example, a contact resistance ruler or a non-contact resistance ruler. The contact resistance ruler may be, for example, a pull rod resistance ruler. Taking the contact resistance ruler as an example, the resistance ruler 2 to be measured may at least include a brush, a control rod, and a connecting bearing.

In the diagnostic system 100, the controller 1 can issue a control command to control the power mechanism 3. For example, the controller 1 can generate a control command by executing a computer-readable execution instruction to control the power mechanism 3 to drive the resistance scale 2 to be tested to operate. When the resistance scale 2 to be tested operates, a feedback signal can be generated and sent back to the controller 1 for reception and storage.

In the embodiment of the present invention, the diagnostic system 100 may further include a display 5 electrically connected to the controller 1, and the display 5 may be used to display a user interface 4. The display 5 may be, for example, a touch display, and the user interface 4 may provide a plurality of options for the user to select an action item to be performed by the power mechanism 3. When the user completes the selection of the aforementioned action item, the controller 1 may generate a corresponding control command corresponding to the target operation to control the power mechanism 3 to actuate.

In a specific embodiment, the touch display can display multiple buttons, and the multiple buttons can correspond to multiple action items, such as increasing the speed, decreasing the speed, maintaining a constant speed, and stopping the resistance ruler 2 to be tested. Therefore, the user can input operation information through the buttons of the touch display as needed to complete the target operation, so that the controller 1 can receive the aforementioned target operation information to adjust the parameters used to control the power mechanism 3.

It should be noted that FIG1 only briefly describes the structure of the diagnostic system 100. In another embodiment, the structure of the diagnostic system 100 of the present invention can be further shown in FIG2. FIG2 provides a specific embodiment of the power mechanism 3, and the diagnostic system 100 is applied to an injection molding machine.

The power mechanism 3 may include, for example, a motor 201, an oil tank 202, a direction valve 203, an oil cylinder 204, an oil outlet pipe 205, an oil return pipe 206, an oil outlet return pipe 207, an oil inlet pipe 208, a connecting rod 209A, and a moving mechanism 210, but the present invention is not limited thereto. The moving mechanism 210 may include, for example, fixed mold plates 211A and 211B, a movable mold wall 212, a mold column 213, a slide rail 214, and a seat 215, but the present invention is not limited thereto. The power mechanism 3 is coupled to the moving mechanism 210 via the connecting rod 209A, and the resistance ruler 2 to be measured is coupled to the moving mechanism 210 via the connecting rod 209B. The resistance ruler 2 to be measured is coupled to the power mechanism 3 via the fixed mold plate 211C.

Furthermore, the oil tank 202 is coupled to the motor 201 through the oil inlet pipe 208, the motor 201 is coupled to the direction valve 203 through the oil outlet pipe 205, the direction valve 203 is coupled to the oil tank 202 through the oil return pipe 206, and the direction valve 203 is coupled to the oil cylinder 204 through the oil return pipe 207. The oil cylinder 204 is coupled to the resistance scale 2 to be measured through the fixed die plate 211C, and the oil cylinder 204 and the resistance scale 2 to be measured are respectively coupled to the fixed die plates 211A and 211B of the moving mechanism 210 through the connecting rods 209A and 209B, so that the power of the oil cylinder 204 can be transmitted through the moving mechanism 210, thereby driving the resistance scale 2 to be measured to move. The motor 201 is used to provide a power source, the oil tank 202 is used to store hydraulic oil, the direction valve 203 is used to change the oil outlet direction and the oil return direction, and the oil cylinder 204 is used to drive the resistance ruler 2 to be measured and the moving mechanism 210.

In addition, the directional valve 203 may have two interfaces, including a first interface (not shown) connected to the oil cylinder 204 through the oil return pipe 207, and a second interface (not shown) connected to the oil tank 202 through the oil return pipe 206. The hydraulic oil can be output from the first interface to the oil cylinder 22 through the oil return pipe 207, and the hydraulic oil can flow back to the oil tank 202 from the second interface through the oil return pipe 206.

For example, when the user selects the target operation of increasing the speed of the resistance ruler 2 to be measured through the user interface 4 displayed on the display 5, the controller 1 will generate a corresponding control signal corresponding to the aforementioned target operation, so that the power mechanism 3 receives the control signal of the controller 1 and starts, and can provide power to make the hydraulic oil output from the oil tank 202, and then enter the motor 201 from the oil inlet pipe 208, so that the hydraulic oil can be pressurized by the motor 201 and output from the oil outlet pipe 205 to the direction valve 203.

Then, the hydraulic oil can be output from the first interface of the direction valve 203 through the oil return pipe 207 to the oil cylinder 204, thereby outputting the power provided by the motor 201 to the oil cylinder 204. The power of the oil cylinder 204 can push the movable mold wall 212A through the connecting rod 209A and the fixed mold plate 211A, so that the movable mold wall 212A slides on the slide rail 214. The kinetic energy of the movable mold wall 212A moving on the slide rail 214 can pull the resistance scale 2 to be measured to move through the fixed mold plate 211B and the connecting rod 209B. However, the above is an example of driving the power mechanism 3 to drive the resistance scale 2 to be measured to increase its speed, and the present invention is not limited to this.

According to the above structure, further reference may be made to FIG. 3 , which is a flow chart of a diagnosis method for a resistance ruler according to an embodiment of the present invention. This diagnosis method is applicable to the above-mentioned diagnosis system 100 , but is not limited thereto.

The following is an explanation of the diagnosis method provided by the embodiment of the present invention by applying it to the embodiment shown in FIG2. As shown in FIG3, the diagnosis method may include configuring the controller 1 to perform the following steps:

Step S100: Generate a control command corresponding to the target operation to control the power mechanism to drive the resistance ruler to be tested.

In the above, how to control the power mechanism 3 to drive the resistance scale 2 to be tested by the control command has been described, and it will not be repeated here. Referring to Figures 2 and 3, the target operation may include one or more of the actions of increasing the speed of the resistance scale 2 to be tested, decreasing the speed, maintaining a constant speed, stopping the operation, etc., or any combination of the above target actions. The control command may be, for example, a drive signal transmitted to the motor 201. For example, in order to increase the speed of the resistance scale 2 to be tested, the control command may be to control the power mechanism 3 so that the speed of the motor 201 outputting hydraulic oil is increased, thereby increasing the speed of the resistance scale 2 to be tested.

In addition, in addition to manually operating the user interface 4 to cause the controller 1 to generate a control command corresponding to the target operation, in other embodiments, the controller 1 can also automatically determine the content of the target operation. Accordingly, the controller 1 can generate a control command corresponding to the aforementioned target operation based on the user's own operation or the target operation automatically determined by the controller 1, so as to control the power mechanism 3 to drive the resistance ruler 2 to be tested to operate, thereby executing subsequent diagnostic actions of the resistance ruler 2 to be tested.

It should be noted that the control command corresponds to the command value data set, and more precisely, the control command corresponds to a plurality of command value data contained in the command value data set. In the present embodiment, in order to adjust the moving speed of the resistance ruler 2 to be tested, the command value data is expressed as a percentage value to represent the speed range in which the resistance ruler 2 to be tested can be executed, and the size of the aforementioned command value data is between 0% and 100%. Therefore, when the command value data is equal to 100%, it means that the moving speed of the resistance ruler 2 to be tested is increased to the maximum speed. In addition, the command value data set may also include a plurality of command timings, that is, the time points corresponding to the generation of the aforementioned command value data. Therefore, the command value data set also defines the corresponding relationship between the aforementioned command value data and the aforementioned command timings.

Step S101: receiving a feedback signal generated by the resistance ruler to be tested, and processing the feedback signal to generate a feedback value data set corresponding to the command value data set.

In this step, the controller 1 may, for example, receive an analog signal generated when the resistance ruler 2 to be tested is displaced as a feedback signal, and record the change of the analog signal and the corresponding timing. The way in which the resistance ruler 2 to be tested generates a feedback signal may, for example, be by monitoring resistance changes or voltage changes. In addition, in order to promptly respond to the operating status of the resistance ruler 2 to be tested, the controller 1 may repeatedly monitor the operating status of the resistance ruler 2 to be tested to generate feedback data. For example, the controller 1 may monitor the operating mode of the resistance ruler 2 to be tested once every 5 milliseconds to generate feedback data. In a preferred embodiment of the present invention, the controller 1 monitors the resistance ruler 2 to be tested once every 1 millisecond.

Specifically, in step S101, the controller 1 may convert the data type of the feedback data received from the resistance ruler 2 to be tested. For example, when the original data type of the feedback signal generated by the resistance ruler 2 to be tested is an analog value, the controller 1 may convert the received analog signal into, for example, a position calculation value, a distance calculation value, a speed calculation value, a voltage calculation value, a start-up time calculation value, and a slope calculation value.

After the controller 1 processes the feedback signal, a feedback value data set corresponding to the command value data set can be generated. The feedback value data set includes a plurality of feedback value data, and each of them corresponds to the aforementioned command value data.

In this step, since the timing of the control command and the timing of the resistance ruler 2 to be tested actually starting to operate are different, it is impossible to directly obtain the feedback value data that truly corresponds to the control command from the feedback data, so the feedback data needs to be further processed. More precisely, the timing of the control command issuance needs to be added with the total delay time (hereinafter referred to as the lag time) required for signal transmission and mechanical component operation, which is the timing of the resistance ruler 2 to be tested actually starting to operate. Therefore, in order to obtain the feedback signal that truly corresponds to the control command, in another embodiment of the present invention, the timing sampling method is further adjusted, which is described in detail with reference to Figure 4 below.

FIG4 is a detailed flow chart of step S101. As shown in FIG4, step S101 further includes:

Step S1010: Record the time when the control command is generated.

In this step, when the controller 1 generates a control command, the issuing time of the control command can be recorded as the command timing, and the command timing can be stored in the storage unit.

Step S1011: Start monitoring the control command corresponding to the command issuance time to obtain the command value data and the corresponding multiple command timings, and monitor the resistance scale to be tested to obtain multiple initial feedback value data.

In this step, the initial feedback value data may include a plurality of initial feedback values and corresponding monitoring timings obtained by the controller 1 from the resistance ruler 2 to be tested. For example, when the controller 1 issues a control command, the controller 1 may simultaneously record the feedback signal generated by the resistance ruler 2 to be tested and the corresponding monitoring timing, for example, by repeatedly monitoring the operation of the resistance ruler 2 to be tested as mentioned above.

Step S1012: taking the command timings after the command issuance time and the lag time period as a plurality of sampling timings, and taking the initial feedback value data corresponding to the sampling timings as the feedback value data, so as to obtain a feedback value data set.

In this step, the purpose of setting the sampling timing is to eliminate the influence of the lag time in order to obtain the initial feedback value data that truly corresponds to the command value data.

That is to say, the sampling timing is the command timing plus the hysteresis time. After obtaining the sampling timing, this step further finds the monitoring timing equal to the sampling timing from all the initial feedback values, and the found initial feedback value data can be used as the feedback value data corresponding to the command value data. Then, after repeatedly executing this step for all the command value data, the feedback value data set can be obtained.

However, the hysteresis time varies according to the different power mechanisms 3, so it is necessary to test different power mechanisms 3 to obtain the hysteresis time. The method for measuring the hysteresis time is shown in the hysteresis time measurement process of FIG5.

FIG5 is a flow chart of the hysteresis time measurement procedure of an embodiment of the present invention. Referring to FIG5 , the measurement procedure includes the following steps:

Step S500: Control the power mechanism to drive the normal resistance scale to move.

For the sake of brevity, the manner in which the normal resistance scale is displaced is not described in detail herein. The normal resistance scale may be, for example, a brand new resistance scale or a resistance scale that has been tested and determined to be not degraded.

Step S501: Record the start-up time required for the displacement of the normal resistance ruler to be greater than the static limit value as the hysteresis time.

The static limit value can be used to determine whether the normal resistance scale actually starts to operate. Specifically, during the operation of the normal resistance scale, vibration and other noise may be generated due to external factors such as the power mechanism 3. In order not to mistake these noises as feedback signals of the displacement of the resistance scale, a static limit value can be set when the controller 1 receives the feedback signal of the resistance scale. The static limit value can be greater than or equal to the displacement caused by the vibration and other noises, so the controller 1 can filter the vibration and other noises through the static limit value. The static limit value may have different preset values according to the different noise levels of the power mechanism 3 in the diagnosis system 100. For example, the static limit value in the embodiment of the present invention may be 5 mm.

When the value of the feedback signal is less than the static limit value, the controller 1 will determine that the feedback signal is noise; on the contrary, when it is a normal resistance ruler, the value of its feedback signal will be greater than the static limit value at the time point, at which time the controller 1 will determine that the normal resistance ruler starts to operate, and accordingly record the current timing as the start time.

Therefore, in this step, when the controller 1 issues a control command, it can record the time when the control command is issued as the starting time Ts, and when the normal resistance ruler starts to operate, it can record the time when it starts to operate as the starting time Tf, and then the two can be subtracted to obtain the lag time Tp.

Thereafter, in step S1012, the command timings after the command issuance time and the lag time are used as a plurality of sampling timings, and the initial feedback value data corresponding to the sampling timings are used as the feedback value data to obtain a feedback value data set.

Please refer to FIG. 3 again, the diagnosis method enters step S102: comparing the command value data set with the corresponding feedback value data set to generate multiple comparison results.

The controller 1 can read the stored command value data set and the corresponding feedback value data set and compare the two, as shown in the following formula (1):

…Formula (1);

In formula (1), To compare the results, is the command value data, The comparison result generated by the corresponding feedback value data represents the difference between the actual operation of the resistance ruler 2 to be tested and the ideal operation.

Considering that the data formats of the command value data and the feedback value data may be different, reference may be made to FIG. 6 , which is a detailed flow chart of step S102 . As shown in FIG. 6 , step S102 further includes the following steps:

Step S1020: Execute a data conversion process on the feedback value data set and the command value data set to compare them under the target data type and generate multiple initial comparison results.

For example, the command value data set may include multiple speed command values, and the feedback value data set may include multiple analog values. In order to compare, the controller 1 may execute a data conversion program to convert the command value data set and the feedback value data set into the same data type so as to compare them in the same data type. For example, the target data type may be one or more of the analog value, position calculation value, distance calculation value, speed calculation value, voltage calculation value, start-up time calculation value and slope calculation value of the resistance scale. Among them, the value of the feedback signal can be directly used as the analog value, the position calculation value and the voltage calculation value can be converted from the analog value, the slope calculation value is the ratio of time to the speed of the resistance scale 2 to be tested, and the speed calculation value can be calculated based on the position calculation value and the corresponding time difference. In addition to the above data types, the velocity calculation value can also be used to obtain the vibration calculation value and the time difference calculation value.

For example, the user can select the target data type according to the needs. In one embodiment of the present invention, the user can select distance as the target data type and instruct the controller 1 to execute step S1020, thereby converting the data types of the command value data set and the feedback value data set into distance for comparison, and generating an initial comparison result that meets the target data type. Among them, the vibration calculation value is the change between the speed value of the control command and the speed value actually fed back by the resistance ruler 2 to be tested, and the time difference calculation value is the change between the timing of the control command and the timing of the resistance ruler 2 to be tested actually starting to operate.

In other embodiments, the controller 1 may also automatically determine the target data type. For example, when the user does not select the target data type, the controller 1 may automatically determine the target data type according to the type of the control command and execute the data conversion procedure accordingly.

Therefore, the command value data and feedback value data that have been unified into the target data form can be substituted into the above formula (1), and the difference can be calculated to obtain the initial comparison result.

Step S1021: Compare the initial comparison results with the standard reference value of the target data type of the resistance tape to be tested to generate the comparison results.

In this step, the standard reference value is the reference value of the normal resistance ruler in the above-mentioned various data forms. For example, if the target data type is a position calculation value, the standard reference value may be the full length of the movable distance of the normal resistance ruler.

That is, the comparison result between the initial comparison result and the standard reference value represents the error between the actual operation of the resistance ruler 2 to be tested and the ideal operation of a normal resistance ruler at the corresponding sampling time. The standard reference value and the initial comparison result can be compared, for example, by obtaining a ratio between the initial comparison result and the standard reference value, and using the ratio as the comparison result of step S1021.

Please refer to FIG. 3 again, the diagnosis method enters step S103: multiple comparison results obtained within a predetermined period of time are statistically analyzed to generate a diagnosis result, and the degradation state and abnormal state of the resistance ruler to be tested are defined according to the diagnosis result.

In this step, the predetermined time period may be the time period from the first sampling sequence to the last sampling sequence. By collecting statistics on all comparison results generated within the predetermined time period, a diagnosis result of the resistance ruler 2 to be tested may be generated.

In detail, the so-called deterioration state refers to the situation that the resistance ruler has abnormal position feedback, slow response feedback and poor stability due to environmental and/or time factors such as temperature, humidity, and application conditions of different speeds. The above-mentioned degradation condition may lead to poor control effect of controller 1, which may interrupt the periodic command receiving behavior of the resistance ruler. In addition, when abnormal position feedback occurs, it will be impossible to pick up the parts normally, causing the production equipment (for example, the injection molding machine mentioned above) to operate abnormally and stop production, thereby reducing production capacity. When a degraded resistor is used in manufacturing equipment such as injection molding machines, the molded products may fail due to material shortage (uneven plastic injection), saturation (too much plastic injection), or product damage, all of which may ultimately lead to reduced machine capacity.

On the other hand, the so-called abnormal conditions include irregular operation of the resistance ruler, interruption of the periodic command receiving behavior of the resistance ruler, drifting of the resistance ruler, etc. Similarly, when an abnormal resistance ruler is used in an injection molding machine, the above abnormal conditions may lead to problems in the production process, such as poor product yield and unstable product production cycle.

Therefore, in embodiments of the present invention, the diagnostic results generated are designed to be used to evaluate the above-mentioned degradation and abnormal conditions.

Regarding the degradation state, reference may be made to FIG. 7 , which is a first detailed flow chart of step S103 . As shown in FIG. 7 , step S103 may further include the following steps:

Step S1030: Obtain all comparison results within a predetermined time period.

For example, the controller 1 can periodically monitor the resistance ruler 2 to be tested within a predetermined time period set or preset by the user to obtain command value data and corresponding feedback value data, and obtain multiple comparison results after comparison.

Step S1031: summing up the comparison results to generate a comparison result sum value.

In this step, the so-called statistics of the comparison results obtained within the predetermined time period may be, for example, all the comparison results within the predetermined time period are summed up to generate a comparison result sum value. However, the present invention is not limited thereto, and other statistical methods may be used to evaluate the data characteristics presented by all the comparison results within the predetermined time period, and evaluation standards may be set on the same basis to evaluate degradation and abnormal conditions.

Step S1032: Compare the sum of the comparison results with the degradation assessment standard to generate a degradation diagnosis result.

In this step, in order to obtain the degradation diagnosis result, the degradation evaluation standard can be used to determine the degradation situation corresponding to the sum of the comparison results. For example, the degradation evaluation standard can include a normal range, a slightly degraded range, a moderately degraded range, and a severely degraded range.

For example, in some embodiments, the normal range can be set to a range in which the sum of the comparison results is greater than or equal to 0% and less than 1%, the mild degradation range can be set to a range in which the sum of the comparison results is greater than or equal to 1% and less than 2%, the moderate degradation range can be set to a range in which the sum of the comparison results is greater than or equal to 2% and less than 5%, and the severe degradation range can be set to a range in which the sum of the comparison results is greater than or equal to 5% and less than 10%, as shown in Table 3 below.

Table 3: Comparison result sum Deterioration Assessment Criteria Deterioration Between 0~1% (including 0%) Normal range No degradation Between 1% and 2% (including 1%) Slightly deteriorated range Slightly deteriorated Between 2% and 5% (including 2%) Moderate degradation range Moderate Deterioration Between 5% and 10% (including 5%) Severe degradation range severe deterioration

That is, when the sum of the comparison results falls within the normal range, it can be determined that the resistance scale 2 to be tested has not deteriorated, or the degree of degradation of the resistance scale 2 to be tested is still within the allowable range of normal operation. For example, when the sum of the comparison results is 0.2%, the controller 1 can determine that the operation of the resistance scale 2 to be tested is normal.

It should be noted that the above-mentioned degradation assessment standard can be set according to user needs. For example, when the user needs to more strictly evaluate the degradation of the resistance ruler 2 to be tested, the degradation assessment standard of the controller 1 can be adjusted. For example, the standard of mild degradation can be reduced to greater than or equal to 0.5% and less than 1%. In this way, the diagnostic system and diagnostic method provided by the embodiment of the present invention can present a more stringent degradation assessment result.

Therefore, it can be imagined that in step S1032, the degradation diagnosis result is based on the degradation evaluation standard corresponding to the sum of the comparison results, thereby presenting the corresponding degradation condition of the resistance ruler 2 to be tested. That is, when the sum of the comparison results falls within the range of slight degradation, it is judged that the resistance ruler 2 to be tested is slightly degraded, such as the components in the resistance ruler 2 to be tested are slightly degraded; when the sum of the comparison results falls within the range of moderate degradation, it is judged that the resistance ruler 2 to be tested is moderately degraded, such as the components in the resistance ruler 2 to be tested are moderately degraded; when the sum of the comparison results falls within the range of severe degradation, it is judged that the resistance ruler 2 to be tested is severely degraded, such as the components in the resistance ruler 2 to be tested are severely degraded.

For abnormal status, please refer to FIG8, which is a second detailed flow chart of step S103. As shown in FIG8, step S103 may further include:

Step S1033: Obtain all comparison results within a predetermined time period.

Step S1034: summing up the comparison results to generate a comparison result sum value.

Step S1035: Compare the comparison result sum value with the abnormal evaluation standard to generate an abnormal diagnosis result.

Among them, steps S1033 and S1034 are the same as steps S1030 and S1031, and will not be repeated here.

In step S1035, in order to obtain an abnormal diagnosis result, an abnormal evaluation standard may be used to determine the abnormal situation corresponding to the sum of the comparison results. For example, the abnormal evaluation standard may include an abnormal surge range and a damaged range.

For example, in some embodiments, the abnormal surge range can be set to a range where the sum of the comparison results is greater than or equal to 10% and less than 99%, and the damage standard can be set to a sum of the comparison results of 100%, as shown in Table 4 below.

Table 4: Comparison result sum Abnormal Assessment Criteria Abnormal situation 10~99% or more (including 10%) Abnormal surge range Abnormal surge 100% Damaged area Damaged

Similarly, the above-mentioned abnormality evaluation standard can be set according to user needs. When the user needs to more strictly evaluate the abnormal situation of the resistance ruler 2 to be tested, the abnormality evaluation standard of the controller 1 can be adjusted.

In step S1035, the abnormal diagnosis result is based on the abnormal evaluation standard corresponding to the sum of the comparison results, thereby presenting the corresponding abnormal situation of the resistance ruler 2 to be tested. That is, when the sum of the comparison results falls within the abnormal surge range, it is judged that the resistance ruler 2 to be tested is partially damaged, such as the components in the resistance ruler 2 to be tested are partially damaged; when the sum of the comparison results reaches the damaged standard, it is judged that the resistance ruler 2 to be tested is damaged, such as the components in the resistance ruler 2 to be tested are damaged.

In addition, the sum of the comparison results can also be used to determine whether the resistance ruler 2 to be tested has an abnormal situation of improper installation. In detail, the speed calculation value can be used as the target data type. When the resistance ruler 2 to be tested performs the target operation of constant speed forward and constant speed backward, the command value data and feedback value data within a predetermined time period can be recorded, and the sum of the comparison results of constant speed forward and constant speed backward can be calculated respectively, so as to determine whether the constant speed forward and constant speed backward of the resistance ruler 2 to be tested have an asymmetric constant speed situation. At the same speed, the sum of the comparison results of constant speed forward and constant speed backward should be the same. When there is a difference between the two, it means that an asymmetric constant speed situation has occurred, that is, the resistance ruler is improperly installed. Therefore, in step S1035, the abnormal evaluation standard may include an asymmetric constant speed range, such as between 1% and 100%, and the method of comparing the comparison result sum with the abnormal evaluation standard is as described above, after calculating the sum of the comparison results of constant speed forward and constant speed backward respectively, the two are subtracted to determine whether the subtraction result is within the asymmetric constant speed range.

It should be noted that the cause of asymmetric constant velocity may be improper installation of the resistance scale, for example, the installation angle between the pull rod of the resistance scale 2 to be measured and the power mechanism 3 is inappropriate, resulting in the pull rod being skewed or deformed when the resistance scale 2 to be measured is displaced.

Furthermore, the controller 1 can also output a notification signal according to the diagnosis result. That is, when the controller 1 outputs the diagnosis result, it can output a corresponding notification signal to remind the user according to the degradation or abnormality corresponding to the diagnosis result. For example, when the diagnosis results show that there are degradation conditions such as slight degradation, moderate degradation, and severe degradation in Table 3, abnormal surges, damage, and the aforementioned asymmetric constant speed in Table 4, push messages such as slight degradation of the resistance ruler, moderate degradation of the resistance ruler, severe degradation of the resistance ruler, partial damage of the resistance ruler, damage of the resistance ruler, and improper installation of the resistance ruler can be displayed through notification signals, thereby reminding the user to eliminate the problem of the resistance ruler and even arrange maintenance schedules for the resistance ruler. If the diagnosis results show that none of the above abnormal conditions or degradation conditions have occurred, the push message will display that the resistance ruler 2 to be tested is in an abnormal state or a non-degraded state.

In addition, the notification signal can be implemented in the form of a light signal, an audio signal or an electronic signal. For example, the controller 1 can transmit the notification signal to the display 5 to display a push notification, control a warning light to flash, or send a warning sound through a speaker.

In addition to the above push mode, the diagnostic system 100 can adopt an emergency shutdown mechanism during the operation of the relevant manufacturing equipment according to the diagnostic result of the resistance ruler 2 to be tested. In some embodiments, the diagnostic method of the present invention may include configuring the controller 1 to execute the emergency shutdown mechanism. The emergency shutdown mechanism can be designed to be executed according to the emergency shutdown standard.

Specifically, when the diagnostic result of the resistance ruler 2 to be tested shows a degradation condition of moderate degradation (inclusive) or above and/or any abnormal condition, the controller 1 will execute an emergency shutdown mechanism to command the resistance ruler 2 to be tested and the power mechanism 3 to stop operating.

In summary, the diagnostic method and diagnostic system for a resistance ruler provided by the present invention can immediately respond to the current degradation or abnormal condition of the resistance ruler, and even predict whether the resistance ruler may deteriorate or become abnormal in the future; in addition, through the setting of the display and the user interface, the degradation or abnormal condition of the resistance ruler can be presented to the user in real time, and even a maintenance reminder message can be sent to the user, so that the user can arrange the maintenance schedule of the resistance ruler in advance. Therefore, for manufacturing equipment that adopts a resistance ruler to execute a position feedback mechanism, the occurrence of sudden production stoppage can be avoided, thereby improving the output and production efficiency of the equipment equipped with the resistance ruler, and saving the maintenance and labor costs required when the equipment equipped with the resistance ruler suddenly stops.

The contents disclosed above are only preferred feasible embodiments of the present invention and are not intended to limit the scope of the patent application of the present invention. Therefore, all equivalent technical changes made using the contents of the specification and drawings of the present invention are included in the scope of the patent application of the present invention.

100: Diagnostic system 1: Controller 2: Resistor to be measured 3: Power mechanism 4: User interface 5: Display 201: Motor 202: Oil tank 203: Directional valve 204: Cylinder 205: Oil outlet pipe 206: Oil return pipe 207: Oil outlet and return pipe 208: Oil inlet pipe 209A, B: Connecting rod 210: Moving mechanism 211A, B, C: Fixed mold plate 212: Moving mold wall 213: Mold column 214: Slide rail 215: Base S100 to S103, S1010 to S1012, S1020, S1021, S1030 to S1035, S501 to S502: Steps

FIG1 is a schematic diagram of a diagnostic system according to an embodiment of the present invention.

FIG. 2 is a schematic diagram of a diagnostic system according to another embodiment of the present invention.

FIG. 3 is a flow chart of a method for diagnosing a resistance ruler according to an embodiment of the present invention.

FIG4 is a detailed flow chart of step S101.

FIG5 is a flow chart of a hysteresis time measurement procedure according to an embodiment of the present invention.

FIG6 is a detailed flow chart of step S102.

FIG. 7 is a first detailed flow chart of step S103.

FIG8 is a second detailed flow chart of step S103.

S100~S103: Steps

Claims (13)

A diagnostic method for a resistance ruler includes configuring a controller to perform the following steps: Generate a control command corresponding to a target operation to control a power mechanism to drive a resistance ruler to be tested, wherein a command value data set is generated according to the control command; Receive a feedback signal generated by the resistance ruler to be tested, and process it to generate a feedback value data set corresponding to the command value data set; Compare the command value data set with the corresponding feedback value data set to generate multiple comparison results; and Count the comparison results obtained within a predetermined time period to generate a diagnosis result, wherein a degradation state and an abnormal state of the resistance ruler to be tested are defined according to the diagnosis result; The command value data set includes a plurality of command value data, the feedback value data set includes a plurality of feedback value data, and the steps of receiving the feedback signal generated by the resistance ruler to be tested and processing to generate the feedback value data set corresponding to the command value data set include: Recording a command issuance time when the control command is generated; Starting to monitor the control command corresponding to the command issuance time to obtain the command value data and the corresponding plurality of command timings, and monitoring the resistance ruler to be tested to obtain a plurality of initial feedback value data; and The command timings after a hysteresis time after the command issuance time are taken as multiple sampling timings, and the initial feedback value data corresponding to the sampling timings are taken as the feedback value data to obtain the feedback value data set; Wherein, the step of controlling the power mechanism to drive the resistance ruler to be tested includes: Executing a hysteresis time measurement program to obtain the hysteresis time, and the hysteresis time measurement program includes configuring the controller to execute the following steps: Controlling the power mechanism to drive a normal resistance ruler displacement; and Recording the start-up time required for a displacement of the normal resistance ruler to be greater than a static limit value as the hysteresis time. In the diagnostic method as described in claim 1, the step of comparing the command value data set with the corresponding feedback value data set to generate the comparison results includes: Executing a data conversion procedure on the feedback value data set and the command value data set to compare and generate multiple initial comparison results under a target data type, wherein the target data type is one or more of the signal value, position calculation value, distance calculation value, speed calculation value, voltage calculation value, start-up time calculation value and slope calculation value of the resistance ruler to be tested; and Comparing the initial comparison results with a standard reference value of the target data type of the resistance ruler to be tested to generate the comparison results. A diagnostic method as described in claim 1, wherein the target operation includes one or more of a plurality of actions performed by the resistance ruler to be tested, the actions including speed increase, speed decrease, maintaining a constant speed, and stopping. The diagnostic method as described in claim 2, wherein the step of summarizing the comparison results obtained within the predetermined time period to generate the diagnostic result includes: Obtaining all the comparison results within the predetermined time period; Adding up the comparison results to generate a comparison result sum value; and Comparing the comparison result sum value with a degradation assessment standard to generate a degradation diagnosis result. The diagnostic method as described in claim 4, wherein the degradation assessment standard includes a normal range, a slightly degraded range, a moderately degraded range, and a severely degraded range, and the step of comparing the comparison result sum with the degradation assessment standard to generate the degradation diagnosis result includes: Determining that the comparison result sum is within the normal range, the slightly degraded range, the moderately degraded range, or the severely degraded range; In response to the comparison result sum being within the normal range, determining that the resistance gauge to be tested is normal; In response to the comparison result sum being within the slightly degraded range, determining that the resistance gauge to be tested is slightly degraded; In response to the sum of the comparison results being within the moderate degradation range, the resistance gauge to be tested is judged to be moderately degraded; and In response to the sum of the comparison results being within the severe degradation range, the resistance gauge to be tested is judged to be severely degraded. A diagnostic method as described in claim 5, wherein the normal range is less than 1%, the mild degradation range is greater than or equal to 1% and less than 2%, the moderate degradation range is greater than or equal to 2% and less than 5%, and the severe degradation range is greater than or equal to 5% and less than 10%. The diagnostic method as described in claim 2, wherein the step of summarizing the comparison results obtained within the predetermined time period to generate the diagnostic result further includes: Obtaining all the comparison results within the predetermined time period; Aggregating the comparison results to generate a comparison result sum value; and Comparing the comparison result sum value with an abnormal assessment standard to generate an abnormal diagnostic result. The diagnostic method as described in claim 7, wherein the abnormal evaluation standard includes a surge range and a damage range, and the step of comparing the comparison result sum with the abnormal evaluation standard to generate the abnormal diagnostic result includes: Determining that the comparison result sum is within the surge range or the damage range; In response to the comparison result sum being within the surge range, determining that the resistance gauge to be tested is partially damaged; In response to the comparison result sum being within the damage range, determining that the resistance gauge to be tested is damaged. A diagnostic method as described in claim 8, wherein the abnormal surge range is greater than or equal to 10% and less than 99%, and the damage range is equal to 100%. The diagnostic method as described in claim 7, wherein the target operation is to perform a constant speed action with the resistance ruler to be tested, the target data type is the speed calculation value, and the step of comparing the comparison result sum with the abnormal evaluation standard to generate the abnormal diagnosis result further includes: Determining whether the comparison result sum is within an asymmetric constant speed range; and In response to the comparison result sum being within the asymmetric constant speed range, determining that the resistance ruler to be tested is improperly installed. A diagnostic method as described in claim 10, wherein the asymmetric constant velocity range is 0% to 100%. The diagnostic method as described in claim 1 includes: Based on the diagnostic result, a notification signal is output to indicate the degradation and/or abnormal state of the resistance ruler to be tested. A diagnostic system for a resistance ruler, which can execute the diagnostic method as described in any one of claims 1 to 12, includes: a controller; a resistance ruler to be tested, electrically connected to the controller; and a power mechanism, coupled to the resistance ruler to be tested; wherein the controller is configured to execute the following steps: generating a control command corresponding to a target operation to control the power mechanism to drive the resistance ruler to be tested, wherein a command value data set is generated according to the control command; receiving a feedback signal generated by the resistance ruler to be tested, processing it to generate a feedback value data set corresponding to the command value data set; comparing the command value data set with the corresponding feedback value data set to generate multiple comparison results; and The comparison results obtained within a predetermined time period are statistically calculated to generate a diagnosis result, wherein a degradation state and an abnormal state of the resistance ruler to be tested are defined according to the diagnosis result.

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