JP3626895B2 - Fault diagnosis system for printing press - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a system for perceive beforehand the failure of many arranged to an unspecified number of the printing press are over Japan and abroad, as well as the determination of these press conditions in accordance with a predetermined rule, net network such as the Internet The present invention relates to a failure diagnosis system that notifies a service base of this situation via a network and that can take measures before a failure occurs to prevent a serious situation in advance.
[0002]
[Prior art]
Printing presses include sheet-fed presses that use paper sheets one by one and web-offset rotary presses that use roll-up paper. Sheet-fed presses are used for commercial printing of posters, calendars, catalogs, etc. In addition, it is used in various industrial fields such as publishing printing, packaging printing of food packaging packages, ceramic printing, building material printing, etc., and even in that type, single color printing machine, multicolor printing machine, single-sided, double-sided printing A wide range of machines. Many of these printing machines are installed not only in Japan but also overseas.
[0003]
Normally, these printing presses have a continuous production plan except for regular maintenance inspections. If the machine stops due to a failure or the like, the production plan may be changed. . There are two types of failures, one that causes a decrease in the quality of printed matter and one that has the property that the printing press itself stops immediately.
[0004]
In general, offset printing using halftone dots is the mainstream printing method for printing presses. However, in addition to deterioration on the printing machine side, printer quality, humidity and type of printed matter, There are various factors such as the water supply condition and ink type. However, the quality type is doubled with halftone dots and lines, misregistration required for double-sided printing or overprinting, There is a decrease in density due to an increase in halftone dot area ratio (dot gain) or an ink transfer failure (trapping failure) during ink overprinting.
[0005]
The printer itself has a nature that stops immediately, such as deterioration of the motor of the printing press, deterioration of gears and bearings, damage due to baking, bending of the transmission system, and failure of the control system. In addition, the above-mentioned deterioration in quality is often caused by factors such as malfunctions and wear of the mechanical system, and even if a certain level of quality recovery is possible when it is detected, the machine may be damaged in the future. Many include factors that lead to outages.
[0006]
In order to deal with these problems, Japanese Patent Application Laid-Open No. 9-52353 discloses a time required for setting various printing conditions, and if it does not fall within a certain time range, it is regarded as abnormal. An apparatus configured to issue an alarm is shown. Patent No. 2955446 is provided with a storage device for storing the operation status of the apparatus, and when an abnormal alarm is issued, the alarm and the storage device are stored. A device is shown in which the operating status is sent to the master station by a modem, and it is determined from the operating status whether or not there is a failure.
[0007]
[Problems to be solved by the invention]
However, all of the methods disclosed in these publications are designed to respond to an alarm when an abnormality or failure occurs. However, in the printing press , if it is dealt with after a failure has occurred as described above, it may take a long time to recover and the production plan may be changed.
[0008]
In addition, when a failure occurs, the user desires an immediate recovery, so that a service person may be dispatched urgently or until the service person arrives, the user and the service base need to exchange over the public line. However, in some cases, such as overseas, dispatching service personnel requires a certain amount of time, and exchanges via public lines are also expensive, and the amount cannot be ignored due to the maintenance burden on the manufacturer.
[0009]
In view of the above-described circumstances, the present invention detects a gray state that is operating normally but will lead to a failure in the future, and allows maintenance to be performed before a failure occurs. The problem is to provide a highly accurate fault diagnosis system that is constantly updated in response.
[0010]
[Means for Solving the Problems]
In view of the above problems, the invention described in claim 1
Fault diagnosis of a printing press in which a large number of user bases having printing presses and service bases that perform maintenance based on information sent from the respective user bases are connected via a network such as the Internet In the system,
The printing machine is a printing machine that outputs a flag signal from a printing operation control device, or each operation detection signal including a sensor detection signal and the operation completion timing signal.
A first threshold level determining an abnormal state without operation completion timing signal from the printing press, the operation detection signal output timing delay state (hereinafter referred to as gray states) the smaller second than the first threshold value is determined for Prepare a threshold level,
The output timing of the operation detection signal of the printing press is compared with the second threshold level, and when the output timing of the operation detection signal exceeds the second threshold level, the corresponding printing press will fail in the future. When notifying the service base via the network that there is a possibility of becoming a gray state and not outputting even if the operation completion timing signal exceeds the first threshold level after the gray state notification It determines that it has successfully restored when the abnormality determination signal generated is not output over a certain time, you and notifies a normal return signal to the service centers via the Internet network.
[0011]
In this way, the first threshold level for determining the abnormal state and the second threshold level lower than the first threshold for determining the gray state that is within the range of the non-abnormal state and may cause a failure in the future are set. By preparing, it is possible to know the gray state by comparing the actual operation detection signal of the machine with these two threshold levels, and it is possible to perform maintenance before it breaks down, A serious situation such as a change can be prevented. In addition, since maintenance can be performed when the machine is operating normally, it can be performed without affecting the production plan.
[0012]
And after detecting the gray state , if no abnormal state (failure) is detected ,
After the gray state notification, it is determined that the abnormality has been returned to normal when the abnormality determination signal generated when the operation detection signal exceeds the first threshold level is not output for a certain period of time, and service is performed via the network. A normal return signal is notified to the base.
[0013]
In other words, even if it becomes gray, if it does not fail for a certain period of time, this state can be determined as normal, and even if the service base prepares for maintenance by contacting gray, it can be canceled. This eliminates the need for useless maintenance and enables efficient service.
[0014]
And when the gray signal is transmitted from a plurality of user bases, the service base side, as described in claim 2 ,
For the user base notified of the gray state, the transmission timing of the service base side monitoring information is changed or the transmission of the user side fault diagnosis information is started.
[0015]
In this way, a plurality of user bases can be monitored sequentially.
[0016]
The first threshold level and the second threshold level are as described in claim 3 .
The second threshold is a timing time for detecting a timing delay of the operation detection signal, and the first threshold is a timing time for detecting the absence of the operation completion timing signal .
[0017]
In other words, if there is a delay in the operation detection signal during the actual operation with respect to the operation detection signal in the normal operation state, as long as the entire system is operating normally, there is a possibility that a failure will occur in the future. On the other hand, the absence of an operation detection signal means that the system is stopped. Therefore, the service base only needs to determine the response by each signal, and efficient service activities can be performed.
[0018]
And these abnormal signal, gray signal, and normal return signal are as described in claim 4 .
Update of the second threshold level for storing the gray state notification signal, normal return signal, and abnormal state notification signal on the service base side for each user or model, and determining the gray state according to the stored contents Is transmitted to the database of the corresponding user base via the network.
[0019]
By storing three types of data in this way, and updating the gray state determination rule with these three types of data and sending it to each user base, it is possible to constantly monitor the state of the machine with the latest information. Thus, it is possible to construct an accurate failure diagnosis system and to prevent a machine failure accurately.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be exemplarily described in detail with reference to the drawings. However, the dimensions, materials, shapes, relative arrangements, and the like of the components described in this embodiment are not intended to limit the scope of the present invention only to those unless otherwise specified. This is just an example.
[0021]
FIG. 1 is a schematic block diagram of a fault diagnosis system for a printing press according to the present invention, FIG. 2 is a flow diagram thereof, FIG. 3 is a configuration diagram of a general sheet-fed printing press, and FIG. FIG. 5 is a timing chart at the time of plate replacement. FIG. 6 is a table listing states (gray state) and failure states (abnormal states) that may cause a future failure at the time of plate replacement. .
[0022]
First, the outline of the present invention will be described. Generally, a control device in a printing press performs operations in order, so that each unit has a sensor, a limit switch, or the like provided when each operation is completed or in each operation part. In many cases, a flag is set when it is notified that the operation of each part or each part is completed, and the operation of the next unit or part is started by referring to the flag.
[0023]
Separately, continuously operating motors, gears, bearings, and transmission systems are equipped with sensors that detect vibration, deflection, voltage, current, etc. It can be monitored.
[0024]
Therefore, in the present invention, these sensor and flag signals during normal operation are stored as time-series timing charts and values during normal operation, and the operation detection signal in the actual operation state is compared with this stored value. Then, a state (gray state) that may cause a failure in the future is detected, and this is notified to the service base to determine the response.
[0025]
At this time, the determination of the failure state and the gray state is performed by setting two threshold levels, a first threshold level for determining the abnormal state and a second threshold level for determining the gray state, as a determination rule. This is performed depending on whether the signal level exceeds these two threshold levels.
[0026]
For example, as an example of the second threshold level that is in the gray state, the system is operating normally, but there is an incorrect switch ON / OFF in which a part of the operation timing of each unit is delayed from the timing of the normal state. Normally, the switch A is activated and then the switch B is activated, but the switch A is not activated, but the switch B is activated. The voltage or current is increased or decreased from the normal state. The vibration has increased.
[0027]
For example, as shown in FIG. 3, the sheet-fed printing press includes a paper feeding unit 1, printing devices 2a, 2b, 2c, 2d,... 2n provided for colors to be printed, a paper discharge unit 3, and the like. Further, each printing apparatus 2 includes a plate cylinder 4 around which a printing plate is wound, a rubber cylinder 5, an impression cylinder 6, an intermediate cylinder 7, and the like. The character image portion of the printing plate wound around the plate cylinder 4 of each printing apparatus 2 is supplied with ink of a corresponding color from an ink supply apparatus (not shown) and transferred to the rubber cylinder 5. Thereafter, the printing paper 8 supplied from the paper supply unit 1 is re-transferred by the impression cylinder 6 to perform printing.
[0028]
Of these, many of the printing plates wound around the plate cylinder 4 can be replaced automatically or semi-automatically in a high-speed printing machine, but the operation is performed in the order shown in FIG. That is, first, the vise is loosened, the old plate 10 fixed as shown in FIG. 4A is released, the plate cylinder 4 is reversed, and the old plate 10 is sent to the outside as shown in FIG. 4B. 4 (c), the new plate 11 is inserted and tightened with a vise, and the new plate 11 is wound around the plate cylinder 4 in FIG. 4 (d) and finally the opposite side is fixed with a vise.
[0029]
When each of these operations is completed, the control device of the printing press sets a flag corresponding to each operation, as indicated by A in the timing chart of FIG. After confirming that the flag is set, the next operation is started.
[0030]
However, as shown in the timing chart marked gray in FIG. 5B, when the discharge timing of the old version is delayed from the normal time, the flag is set, but the subsequent operation is normally performed, Since the previous version was delayed for some reason, it is determined that the state is gray because it may lead to a failure in the future. Further, as shown in the timing chart of C in FIG. 5, when the flag indicating completion of old version discharge is not raised and the operation of the system is stopped, it is determined as a failure (abnormal state).
[0031]
In other words, the second threshold value in this case is that the system is operating normally and a certain operation is delayed from the normal time. This is because the old version of the receiving device did not grasp the old version well or grabbed the old version. The cause of the operation of the actuator moving to the position being slow for some reason such as friction may be considered. The first threshold value is a case where the old plate ejection operation does not end even after a predetermined time has elapsed. In this case, the system is stopped.
[0032]
In other words, when the operation of changing the plate is roughly ordered, there are 8 steps from loosening the vise to finally attaching the new plate and tightening the vise. Each of these steps is shown in the table of FIG. The gray state and the failure state exist as shown in FIG. Therefore, in such operations performed in time series, if the system is operating normally even if there is a time delay or advance, the second threshold value is set to the gray state, and when the operation is not completed for a certain time or more A failure is determined as the first threshold.
[0033]
However, even if a gray state occurs as shown in FIG. 5B, for example, when there is a steady delay in the discharge of the old version every time, and when there is no sign of a future failure even after investigating the related mechanism, The delay should also be determined as a normal state. In such a case, the interval of the old plate discharge portion in the timing chart of FIG. 5A, which has been normal until now, is included in the comparison rule as normal to the interval in B of FIG. If it is updated as a new rule, a more reliable fault diagnosis system can be constructed.
[0034]
FIG. 1 is a schematic block diagram of a fault diagnosis system for a printing press according to the present invention, and FIG. 2 is a flowchart thereof. In the figure, 20 is a sensor provided in each operation part of the device as described above, 21 is a switch for turning on / off the operation of each unit, 22 is an A / D converter for analog / digital conversion of the signal from the sensor 20, Reference numeral 23 denotes a control device for a printing press such as a printing press. As described above, this control device is based on the signals from the sensor 20 and the switch 21 and the operation completion signals from the units and devices constituting the printing press. A flag is set for each operation to control the operation. Moreover, the signal from the sensor which detects a vibration, bending, a voltage, or an electric current sends out the digital signal from an A / D converter. These flags and digital signals are sent to the CPU 24 as the operation detection signals described above. Reference numeral 25 denotes an operation detection signal storage unit for storing the operation detection signal. Reference numeral 26 denotes a timing chart of the operation detection signal during normal operation and vibration and deflection amounts from the sensor as the first and second threshold values. It is a determination rule storage unit. Note that reference numeral 27 in which the blocks 20 to 26 are surrounded by a dotted line corresponds to one printing machine such as a printing machine, and when there are a plurality of printing machines, the same number of blocks are prepared.
[0035]
Reference numeral 28 denotes a LAN (local area network) for connecting the printers when there are a plurality of printers , and is not necessary when there is only one printer. 29 is an encryption processing unit that encrypts the signal and the operation detection signal stored in the operation detection signal storage unit 25 when the CPU 24 detects the gray state or the failure state as described above, and sends the data as it is. It is not necessary if it is okay. Reference numeral 30 denotes a user-side mail server, and the blocks described above are placed at the user-side base.
[0036]
Reference numeral 31 denotes the Internet, which is not limited to the Internet, and uses an intranet, a dedicated line, a wide area information communication network (WAN), or a network including communication means such as a public line and a mobile phone. 32 is a service side mail server, and 33 is an encryption processing unit that decrypts the encryption of the data sent to it, and is not necessary when the data may be sent as it is as described above. 34 is a determination unit that determines whether or not user data will cause a failure in the future, 35 is a model determination rule database that stores the latest determination rule for each model, 36 is a machine installation date for each user and model, and maintenance record , A per-user model-specific database 37 that stores data related to signals notified of a gray state or a failure state, etc., is a display device. The blocks 32 to 37 described above are placed at the service base.
[0037]
Next, the operation of the present invention will be described with reference to the flow chart of FIG. 2. First , the control device 23 of the printing press generates a flag signal generated by a signal from the sensor 20, the switch 21 or the like, a digital signal after A / D conversion, and the like. The motion detection signal is sent to the CPU 24, stored in the motion detection signal storage unit 25, and compared with the normal rule stored in the determination rule storage unit 26 by the CPU 24 in S40 of FIG.
[0038]
Then, it is determined whether or not the result is within the range of the normal rule in S41 of FIG. 2. If it is within the range, the process returns to S40 and the comparison is continued. If the result is out of the range, the first threshold level or the second threshold level is determined. The result and the operation detection signal determined to be out of the range of the normal rule stored in the operation detection signal storage unit 25 are sent to the service base in S42 as failure diagnosis information. The communication of the failure diagnosis information is sent to the Internet 31 as mail through the LAN 28, the encryption processing unit 29, and the user side mail server 30, and reaches the mail server 32 at the service base.
[0039]
At the service base, the encryption of the received mail is decrypted by the encryption processing unit 33 and sent to the user data determination unit 34. Then, the user data determination unit 34 determines whether the content of the data sent in S43 of FIG. 2 is the first threshold level or the second threshold level, and if it is the first threshold level (failure), the process proceeds to S44. Display on the display device 37 and arrange to dispatch a service person to the user. On the other hand, if the sent data is the second threshold level, the contents stored in the model-specific determination rule database 35 and the user-specific model-specific database 36 are referred to in S45 and compared with the determination rule for the corresponding model. The
[0040]
If it is determined in S46 that there is a possibility of a failure in the future, service is arranged in S47. In other cases, that is, there is no problem, or it is necessary to monitor and determine the result in the future. It is confirmed whether the determination rule of the user base is the latest, and if it is not the latest, the result and the latest determination rule are sent to the encryption processing unit 33 in S48, and the Internet 31 is sent from the service side mail server 32. To the user base.
[0041]
At the user base, the contact sent in S49 in FIG. 2 is received by the user side mail server 30, decrypted by the encryption processing unit 29, and sent to the CPU 24 via the LAN. The contents are confirmed in S50, and if it is determined that there is no problem, the process returns to S40 and returns to the normal operation. If it is determined that monitoring is necessary and the latest rule is sent together, the latest rule is sent to and stored in the determination rule storage unit 26, and the latest rule stored in the determination rule storage unit 26 in S51. And the operation detection signal are compared.
[0042]
As a result, when it is detected in S52 that the first threshold level has been exceeded (failure), as described above, this is communicated to the service base via the user side mail server 30, and the service base Make arrangements to dispatch.
[0043]
On the other hand, if there is no abnormality in S52, it is determined whether or not a certain time n has elapsed in S53, and if it has not elapsed, the process returns to S51 and the same is repeated. If there is no abnormality, it is determined that the operation has returned to normal, and the routine returns to S40, which is notified to the service in S54. That is, when the state of the second threshold value determined as the gray state does not go to the state of the first threshold value, this state can also be handled as a normal state, and the service base receives the notification of the gray state and receives the service status. Even if you are ready, you can unlock it at this point.
[0044]
As described above, the communication is performed by the encryption processing unit 29 and the user side mail server 30 via the Internet 31. The service side base that has received the communication passes through the service side mail server 32 and the encryption processing unit 33 as described above. This notification is sent to the user data determination unit 34. Then, the user data determination unit 34 updates the contents of the maintenance record in the model-specific determination rule database 35 and the user-specific model-specific database 36 in S55, and returns the update result to the user base in S56. Update the contents of the rule storage unit.
[0045]
In the above description, the mail servers 30 and 32 are used for sending out the failure diagnosis information. However, this is not limited to the mail server. The user side base uses a WWW browser and the service side uses a WWW server. The gateway may be used to exchange signals.
[0046]
In this case, the service-side base CGI (Common Gateway Interface) program is started with the data sent from the user-side base, the contents of the model determination rule database 35 are read through the gateway, and displayed on the user-side WWW browser. Therefore, a determination may be made.
[0047]
However, in this case, it may be difficult to send out the contents of the database if there are multiple users accessing the gray status at the same time. Therefore, the gray status is notified first, and the service base side monitoring information (model determination rule) The transmission timing of (contents of the database) may be made different, or the transmission of user side failure diagnosis information may be started, and the order may be determined and determined.
[0048]
【The invention's effect】
As described above, the first threshold level for determining the abnormal state and the first threshold level that is within the range of the non-abnormal state and is lower than the first threshold for determining the gray state that may cause a failure in the future. By preparing two threshold levels, it is possible to know the gray state by comparing these two threshold levels with the actual motion detection signal of the machine, and it becomes possible to perform maintenance before failure occurs. It is possible to prevent a serious situation such as a production plan change due to a failure. In addition, since maintenance can be performed when the machine is operating normally, it is possible to carry out the process without affecting the production plan.
[0049]
In addition, even if a gray state is detected, if the failure does not occur for a certain period of time, it is determined that this state is normal, so that the service base can cancel it even if it prepares for maintenance by contacting the gray state. This eliminates the need for useless maintenance and enables efficient service.
[0050]
In addition, by updating the contents of the database for determining the gray state with the three types of data of the gray state notification signal, the normal return signal, and the abnormal state notification signal, and sending it to each user base, can always monitor the state of the printing machinery with the latest information, it is possible to accurately prevent the failure of the machine it is possible to construct an accurate fault diagnosis system.
[Brief description of the drawings]
FIG. 1 is a schematic block diagram of a fault diagnosis system for a printing press according to the present invention.
FIG. 2 is a schematic flowchart of a fault diagnosis system for a printing press according to the present invention.
FIG. 3 is a diagram for explaining a configuration of a general sheet-fed printing press.
FIG. 4 is a diagram for explaining an order of plate exchange in a printing machine.
FIG. 5 is a timing chart at the time of plate replacement in the printing press.
FIG. 6 is a table showing a list of states (gray state) and failure states that may cause a failure at the time of plate replacement.
[Explanation of symbols]
20 sensor 21 switch 22 A / D converter 23 control device 24 of printing press CPU
25 Operation detection signal storage unit 26 Judgment rule storage unit 28 LAN
29 Cryptographic processing unit 30 User side mail server 31 Internet 32 Service side mail server 33 Cryptographic processing unit 34 User data determining unit 35 Model-specific determination rule database 36 User-specific model database 37 Display device

Claims (4)

Fault diagnosis of a printing press in which a large number of user bases having printing presses and service bases that perform maintenance based on information sent from the respective user bases are connected via a network such as the Internet In the system,
The printing machine is a printing machine that outputs a flag signal from a printing operation control device or each operation detection signal including a sensor detection signal and the operation completion timing signal,
A first threshold level determining an abnormal state without operation completion timing signal from the printing press, the operation detection signal output timing delay state (hereinafter referred to as gray states) the smaller second than the first threshold value is determined for Prepare a threshold level,
The output timing of the operation detection signal of the printing press is compared with the second threshold level, and when the output timing of the operation detection signal exceeds the second threshold level, the corresponding printing press will fail in the future. When notifying the service base via the network that there is a possibility of becoming a gray state and not outputting even if the operation completion timing signal exceeds the first threshold level after the gray state notification A fault diagnosis system for a printing press, characterized in that when the generated abnormality determination signal is not output for a predetermined time or more, it is determined that the operation has returned to normal, and a normal return signal is notified to the service base via the network. 2. The failure diagnosis of a printing press according to claim 1, wherein, for the user base notified of the gray state, transmission timing of service base side monitoring information is changed or transmission of user side failure diagnosis information is started. system. 2. The printing according to claim 1, wherein the second threshold is a timing time for detecting a timing delay of the operation detection signal, and the first threshold is a timing time for detecting the absence of the operation completion timing signal. Machine fault diagnosis system. Update of the second threshold level for storing the gray state notification signal, normal return signal, and abnormal state notification signal on the service base side for each user or model and determining the gray state based on the stored contents The failure diagnosis system for a printing press according to claim 1, wherein the failure diagnosis system is transmitted to a database of a corresponding user base via a network.

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