Patent Application
20070213855
The present invention relates to a diagnostic information providing apparatus for a construction machine and a diagnostic information display system for a construction machine. More particularly, the present invention relates to a diagnostic information providing apparatus for a construction machine and a diagnostic information display system for a construction machine, such as a large-sized hydraulic excavator.
A construction machine, in particular a large-sized hydraulic excavator, is used for excavation of earth and stones in a very wide worksite, for example. In general, such a large-sized hydraulic excavator is continuously operated for the purpose of increasing productivity. If any abnormality occurs, the operation of the hydraulic excavator must be stopped for repair. Depending on a degree of the abnormality, it may happen that the operation of the hydraulic excavator must be ceased for a long period. In such a case, because production work using that hydraulic excavator must be suspended, it is required to change steps of a production schedule.
In view of such a situation, a monitoring device for a hydraulic working machine is proposed in which, when an abnormality is detected in, e.g., an engine system, status variables (detection data) related to an engine operating state in a certain period until the detection of the abnormality are selectively stored and accumulated as operation data while being displayed (see, e.g., Patent Document 1). With the proposed related art, abnormality diagnosis can be advantageously made and trouble-shooting can be promptly performed by using the operation data in the certain period until the detection of the abnormality.
Patent Document 1: JP,A 7-119183
However, the above-mentioned related art still has room for improvement in the following point.
In the above-mentioned related art, the operation data is acquired only after the detection of the abnormality in the engine system, for example, with intent to utilize the operation data for subsequent failure diagnosis and to promptly perform the trouble-shooting, thereby cutting a suspension time of the hydraulic excavator. Usually, if any abnormality is detected, the operation of the hydraulic excavator must be stopped and, depending on a degree of the abnormality, the operation must be ceased for a long period. On the other hand, as described above, the large-sized hydraulic excavator is required to be continuously operated for the purpose of increasing productivity. In order to meet such a requirement, the suspension period due to a failure has to be reduced as short as possible. Stated another way, when an operator intuitively perceives a sign indicating, e.g., a drop of engine output, there is a possibility of finding an abnormality from the sign before it actually occurs. Nevertheless, the above-mentioned related art does not take into account such a possibility and still has room for further improvement in a point of cutting the suspension period of the hydraulic excavator.
The present invention has been made in consideration of the above-described problems with the related art, and its object is to provide a diagnostic information providing apparatus for a construction machine and a diagnostic information display system for a construction machine, which can find an abnormality before it actually occurs and can reduce the suspension period of the construction machine.
(1) To achieve the above object, a diagnostic information providing apparatus for a construction machine, according to the present invention, comprises detection means for detecting status variables related to an operating state of the construction machine or ambient environment; storage means for storing combinations between a plurality of snapshot items and one or more status variables related to each of the snapshot items in advance; status variable display control means for acquiring or extracting status variable data, which is regarded as being related based on the stored combinations, from corresponding detected signals of the detection means with respect to the snapshot item selected by a selection command from an operator, thereby displaying the status variable data on display means; failed part determining means for comparing each of the status variables or a value computed based on a plurality of status variables, which are contained in the acquired or extracted status variable data, with a corresponding predetermined reference value range, and determining a failure of a corresponding part when the status variable or the computed value is outside the predetermined reference value range; and failed part display control means for displaying the failed part or the related status variable, which has been determined by the failed part determining means, on the display means.
As a sign representing an abnormality in an engine system, for example, there appears a drop of engine output in some cases. The drop of engine output is intuitively perceived by an operator, but it is generally not detected as an abnormality. In the present invention, when the operator manipulates operating means, e.g., a keypad and commands selection of one snapshot item, the status variable display control means acquires or extracts status variable data, which is related to the selected snapshot item, thereby displaying the status variable data on the display means. On that occasion, the failed part determining means compares each of the status variables or a value computed based on a plurality of status variables, which are contained in the acquired or extracted status variable data (namely, the status variables displayed on the display means), with a corresponding predetermined reference value range (i.e., a predetermined reference value range set and stored in advance). When the status variable or the computed value is outside the predetermined reference value range, the failed part determining means determines a failure of a corresponding part (more specifically, a failure that occurs to such an extent as not generating an abnormality as a detection result). The failed part display control means displays the failed part or the related status variable, which has been determined by the failed part determining means, on the display means.
Thus, according to the present invention, the status variable data related to the snapshot item selected by the selection command from the operator is displayed on the display means, and whether a part corresponding to each status variable is failed is determined. If a failure is determined, the failed part or the related status variable is displayed on the display means. Therefore, the operator can find an abnormality before it actually occurs. Also, any serviceman can easily specify the failed part regardless of experiences and skills of individual servicemen. As a result, it is possible to cut the operation suspended time of a hydraulic excavator, and to increase productivity.
(2) Also, to achieve the above object, a diagnostic information providing apparatus for a construction machine, according to the present invention, comprises detection means for detecting status variables related to an operating state of the construction machine or ambient environment; storage means for storing combinations between a plurality of snapshot items and one or more status variables related to each of the snapshot items in advance; recording means for acquiring or extracting status variable data, which is regarded as being related based on the stored combinations and falls within a predetermined time, from corresponding detected signals of the detection means with respect to the snapshot item selected by a selection command from an operator, thereby recording the status variable data in the storage means; status variable display control means for playing back and displaying changes of the status variable data, which is stored in the storage means and falls within the predetermined time, on the display means in accordance with a command from an operator; failed part determining means for comparing each of the status variables or a value computed based on a plurality of status variables, which are contained in the status variable data falling within the predetermined time, with a corresponding predetermined reference value range, and determining a failure of a corresponding part when the status variable or the computed value is outside the predetermined reference value range; and failed part display control means for displaying the failed part or the related status variable, which has been determined by the failed part determining means, on the display means.
With the present invention, for example, in the case of the operator intuitively perceiving a sign indicating an abnormality, e.g., a drop of engine output, during the operation, when the operator manipulates operating means, e.g., a keypad and commands selection of one snapshot item, the recording means acquires or extracts the status variable data related to the selected snapshot item and falling within the predetermined time (i.e., the so-called manual snapshot data) in the storage means. Thereafter, when a serviceman, for example, manipulates the operating means, e.g., the keypad and selects the manual snapshot data which is stored in the storage means and falls within the predetermined time, the status variable display control means plays back and displays changes of the status variable data falling within the predetermined time on the display means. On that occasion, the failed part determining means compares each of the status variables or a value computed based on a plurality of status variables, which are contained in the status variable data falling within the predetermined time (namely, the status variables displayed on the display means), with a corresponding predetermined reference value range. When the status variable or the computed value is outside the predetermined reference value range, the failed part determining means determines a failure of a corresponding part. The failed part display control means displays the failed part or the related status variable, which has been determined by the failed part determining means, on the display means.
Thus, according to the present invention, changes of the status variable data stored in the storage means and falling within the predetermined time are played back and displayed in accordance with the command from the operator, and whether a part corresponding to each status variable is failed is determined. If a failure is determined, the failed part or the related status variable is displayed on the display means. Therefore, the operator can find an abnormality before it actually occurs. Also, any serviceman can easily specify the failed part regardless of experiences and skills of individual servicemen. As a result, similarly to the case of above (1), it is possible to cut the operation suspended time of a hydraulic excavator, and to increase productivity.
(3) In above (1) or (2), preferably, the failed part determining means compares the status variable or the computed value with each of a plurality of corresponding reference value ranges to determine a failure in a stepwise manner, and the failed part display control means displays a stage of the failure, which have been determined by the failed part determining means, on the display means.
(4) In any one of above (1) to (3), preferably, the status variable display control means displays changes of the status variable and a minimum value and a maximum value of the status variable within a predetermined time.
(5) Further, to achieve the above object, a diagnostic information display system for a construction machine, according to the present invention, comprises detection means for detecting status variables related to an operating state of a construction machine or ambient environment; display means disposed inside a cab of the hydraulic excavator; storage means for storing combinations between a plurality of snapshot items and one or more status variables related to each of the snapshot items in advance; status variable display control means for acquiring or extracting status variable data, which is regarded as being related based on the stored combinations, from corresponding detected signals of the detection means with respect to the snapshot item selected by a selection command from an operator, thereby displaying the status variable data on the display means; failed part determining means for comparing each of the status variables or a value computed based on a plurality of status variables, which are contained in the acquired or extracted status variable data, with a corresponding predetermined reference value range, and determining a failure of a corresponding part when the status variable or the computed value is outside the predetermined reference value range; and failed part display control means for displaying the failed part or the related status variable, which has been determined by the failed part determining means, on the display means.
(6) Still further, to achieve the above object, a diagnostic information display system for a construction machine, according to the present invention, comprises detection means for detecting status variables related to an operating state of a construction machine or ambient environment; display means disposed inside a cab of the hydraulic excavator; storage means for storing combinations between a plurality of snapshot items and one or more status variables related to each of the snapshot items in advance; recording means for acquiring or extracting status variable data, which is regarded as being related based on the stored combinations and falls within a predetermined time, from corresponding detected signals of the detection means with respect to the snapshot item selected by a selection command from an operator, thereby recording the status variable data in the storage means; status variable display control means for playing back and displaying changes of the status variable data, which is stored in the storage means and falls within the predetermined time, on the display means in accordance with a command from an operator; failed part determining means for comparing each of the status variables or a value computed based on a plurality of status variables, which are contained in the status variable data falling within the predetermined time, with a corresponding predetermined reference value range, and determining a failure of a corresponding part when the status variable or the computed value is outside the predetermined reference value range; and failed part display control means for displaying the failed part or the related status variable, which has been determined by the failed part determining means, on the display means.
(7) In above (5) or (6), preferably, the failed part determining means compares the status variable or the computed value with each of a plurality of corresponding reference value ranges to determine a failure in a stepwise manner, and the failed part display control means displays a stage of the failure, which have been determined by the failed part determining means, on the display means.
(8) In any one of above (5) to (7), preferably, the status variable display control means displays changes of the status variable and a minimum value and a maximum value of the status variable within a predetermined time.
According to the present invention, the status variable data related to the snapshot item or the status variable data stored in the storage means and falling within the predetermined time is displayed on the display means, and whether a part corresponding to each status variable is failed is determined. If a failure is determined, the failed part or the related status variable is displayed on the display means. Therefore, the operator can find an abnormality before it actually occurs. Also, any serviceman can easily specify the failed part regardless of experiences and skills of individual servicemen. As a result, it is possible to cut the operation suspended time of a hydraulic excavator, and to increase productivity.
One embodiment of a diagnostic information providing apparatus for a construction machine according to the present invention will be described below with reference to the drawings.
A hydraulic excavator 1 comprises a track body 12, a swing body 13 installed on the track body 12 in a swingable manner, a cab 14 installed in a front portion of the swing body 13 on the left side, and a front operating mechanism (excavating device) 15 mounted to a front central portion of the swing body 13 in a vertically rotatable manner. The front operating mechanism 15 is made up of a boom 16 rotatably mounted to the swing body 13, an arm 17 rotatably mounted to a fore end of the boom 16, and a bucket 18 rotatably mounted to a fore end of the arm 17. A (machine-side) controller 2 is installed in the cab 14.
While the hydraulic excavator 1 is shown in
In
The hydraulic pumps 21a, 21b are rotated, for delivery of a hydraulic fluid, by two diesel engines 32 (only one of which is shown in
Control lever units 33, 34, 35 and 36 are disposed respectively in association with the control valves 22a, 22b-26a, 26b. When a control lever of the control lever unit 33 is manipulated in one direction X1 of perpendicularly crossed directions, an arm-crowding pilot pressure or an arm-dumping pilot pressure is produced and applied to the arm control valve 23. When the control lever of the control lever unit 33 is manipulated in the other direction X2 of the perpendicularly crossed directions, a rightward-swing pilot pressure or a leftward-swing pilot pressure is produced and applied to the swing control valve 25.
When a control lever of the control lever unit 34 is manipulated in one direction X3 of perpendicularly crossed directions, a boom-raising pilot pressure or a boom-lowering pilot pressure is produced and applied to the boom control valves 22a, 22b. When the control lever of the control lever unit 34 is manipulated in the other direction X4 of the perpendicularly crossed directions, a bucket-crowding pilot pressure or a bucket-dumping pilot pressure is produced and applied to the bucket control valve 24. Further, when control levers of the control lever units 35, 36 are manipulated, a left-track pilot pressure and a right-track pilot pressure are produced and applied to the track control valves 26a, 26b. Incidentally, the control lever units 33-36 are disposed in the cab 14 along with the controller 2.
Sensors 40-46, 47a, 47b, 47c, etc. are disposed in the hydraulic system 20 constructed as described above. The sensor 40 is a pressure sensor for detecting, as an operation signal of the front operating mechanism 15, the boom-raising pilot pressure in this embodiment. The sensor 41 is a pressure sensor for detecting, as a swing operation signal, the swing pilot pressure taken out through a shuttle valve 41a. The sensor 42 is a pressure sensor for detecting, as a track operation signal, the track pilot pressure taken out through shuttle valves 42a, 42b and 42c.
The sensor 43 is a sensor for detecting the on/off state of a key switch of the engine 32, the sensor 44 is a pressure sensor for detecting the delivery pressure of the hydraulic pumps 21a, 21b, i.e., the pump pressure, taken out through a shuttle valve 44a, and the sensor 45 is an oil temperature sensor for detecting the temperature of working oil (i.e., oil temperature) in the hydraulic system 20. The sensor 46 is a revolution speed sensor for detecting the revolution speed of the engine 32. The sensor 47a is a fuel sensor for detecting the amount of fuel injected by the fuel injector (i.e., fuel consumption), the sensor 47b is a pressure sensor for detecting the turbo boosted pressure of the engine 32, and the sensor 47c is a temperature sensor for detecting the temperature of coolant (radiator water) for cooling the engine 32 (e.g., the temperature in an upper manifold or the temperature at an outlet). In addition, though not shown for the sake of brevity of the drawing, there are disposed other various sensors, e.g., a sensor for detecting the exhaust temperature for each cylinder, a sensor for detecting the throttle position of an electronic governor, a sensor for detecting a fuel level, a sensor for detecting a battery voltage, a sensor for detecting the temperature of an intake manifold, a sensor for detecting the pressure in the upper manifold of the radiator, a sensor for detecting the air temperature at a front surface of the radiator, a sensor for detecting the inlet pressure (hydraulic pressure) of a hydraulic motor for a fan for cooling the radiator, a sensor for detecting the delivery pressure of a coolant pump, a sensor for detecting the temperature of an intercooler, and sensors for detecting the inlet and outlet temperatures and the outlet pressure of an oil cooler, which are associated with the engine 32, a sensor for detecting a boom angle, which is associated with the boom 16, as well as a sensor for detecting the atmospheric pressure and a sensor for detecting the atmospheric temperature, which are associated with the ambient environment. Signals detected by those sensors 40-46, 47a, 47b, 47c, etc. (hereinafter referred to simply as the “sensor 40, etc.” as required) are all sent to and collected in the controller 2.
While the above description has been made, by way of example, in connection with the case of the control levers being each of the hydraulic pilot type, the present invention is not limited to that case, and each control lever may be of the so-called electric lever type. In such a modification, a signal representing the operating state is obtained by, instead of detecting the pilot pressure, using an electric output (command signal) from a control lever unit of the electric lever type as it is.
The controller 2 collects the status variables related to the operating state of the hydraulic excavator 1 and the ambient environment, which are detected by the sensor 40, etc., and it displays various kinds of information in the cab 14 based on the detected results. The most important feature of this embodiment resides in display mode for presenting the information in the cab 14.
In
Within the cab 14, a display unit 50 and a keypad 51 are further disposed as display means and operating means, respectively, which constitute principal components of the diagnostic information providing apparatus for the construction machine according to the present invention. The display unit 50 is disposed on a front wall of the cab 14 in a position that is located forward of the operator sitting in the cab 14 on the left side and is located at a level slightly higher than the control lever 33a in the vertical direction. The keypad 51 is disposed leftward of the control lever 33a and the left console 48L which are disposed on the left side of the seat 14A.
Additionally, the controller 2 is placed in an appropriate position within the cab 14 (e.g., under the seat 14A).
As shown in
The basic data display area 50A includes a tachometer display area 50Aa, a radiator coolant temperature display area 50Ab, and a turbo boosted pressure display area 50Ac for one engine 32 of the two engines, a tachometer display area 50Ad, a radiator coolant temperature display area 50Ae, and a turbo boosted pressure display area 50Af for the other engine 32, a fuel level display area 50Ag, a working oil temperature display area 50Ah, an atmospheric temperature display area 50Ai, and a battery voltage display area 50Aj.
The alarm/failure display area 50B includes an alarm display area 50Ba for displaying alarms related to one engine 32 of the two engines and various indicators, an alarm display area 50Bb for displaying alarms related to the other engine 32 and the hydraulic system, and a failure display area 50Bc for displaying an abnormality (in the form of, e.g., a preset failure code) in any component of control equipment and a communication system, such as the sensor 40, etc. and the controller 2.
As shown in
In
The input/output interface 2a receives, from the sensor 40, etc., detected signals of the pilot pressures for the front operating mechanism 15, the swing and the track, a detected signal of key-switch-on for the engine 32, detected signals of the pump pressures of the pumps 21a, 21b, a detected signal of the oil temperature, a detected signal of the revolution speed of the engine 32, a detected signal of the coolant temperature, a detected signal of the fuel consumption, a detected signal of the turbo boosted pressure, a detected signal of the exhaust temperature of the engine 32, a detected signal of the throttle position, a detected signal of the intake manifold temperature, a detected signal of the pressure in the upper manifold of the radiator, a detected signal of the air temperature at the front surface of the radiator, a detected signal of the inlet pressure of the hydraulic motor for a fan for cooling the radiator, a detected signal of the delivery pressure of the coolant pump, a detected signal of the intercooler temperature, detected signals of the inlet and outlet temperatures and the outlet pressure of the oil cooler, a detected signal of the boom angle, a detected signal of the atmospheric pressure, a detected signal of the atmospheric temperature, and so on. Additionally, when the engine 23 is in a state of derating control (=known control of reducing an engine output when, for example, the coolant is overheated or the oil pressure is lowered), the controller may also monitor such a state by detecting a derating control signal and receive the detected derating control signal for use in other control.
The CPU 2c executes predetermined arithmetic and logical processing based on those detected signals and stores the processing results in the memory 2d. In that process, the CPU 2c employs the timer (including the clock function) 2e as required. Also, the timer 2e may be used to set the interval (period) for taking in the detected signals from the sensor 40, etc.
Though not shown, the controller 2 further comprises a ROM serving as a recording medium which stores control programs for operating the CPU 2c so as to execute the predetermined arithmetic and logical processing, and a RAM serving as storage means which temporarily stores data in the course of the processing.
In
The signal input processing section 2A takes in the detected signals from the sensor 40, etc. and the operational signal X from the keypad 51, and outputs those signals to the control sections 2B-2G after executing a predetermined reception process.
The basic data display control section 2B corresponds to the basic data display area 50A (see
The alarm display control section 2C corresponds to the alarm data display areas 50Ba, 50Bb (see
The alarm on/off determining function determines, based on the detected signals (status variable data) from the sensor 40, etc., whether each of the detected signals is within a preset threshold range (i.e., a range where an abnormality is not detected). If the detected signal is not within the preset threshold range, this is determined as indicating a state where an alarm is to be issued (i.e., an abnormal state), and alarm information is outputted to the alarm display signal producing function.
The alarm display signal producing function receives the alarm information and outputs display signals (alarm display signals) for presenting corresponding alarm indications to the alarm display areas 50Ba, 50Bb on the display unit 50. In the alarm display areas 50Ba, 50Bb, each alarm is indicated in the form of, e.g., an alarm mark preset in relation to the kind of the alarm. Although a detailed description of individual alarms is omitted here, examples of alarms regarding the engine 32, which are in common to both the alarm display areas 50Ba, 50Bb, include a fuel level drop alarm, a radiator coolant level drop alarm, a radiator coolant overheat alarm, and an engine exhaust temperature overheat alarm. Examples of alarms regarding the hydraulic system, which belong to the alarm display area 50Bb, include a working oil level drop alarm and a working oil overheat alarm.
Of the above-described two functions, the alarm on/off determining function may be separately provided outside the controller 2. In other words, each sensor may determine by itself, based on comparison with a threshold, whether the detected signal is normal or abnormal, and if an abnormality is determined, it may transmit alarm information to the alarm display signal producing function of the controller 2. As an alternative, another control unit (sub-controller) may be provided for each sensor (or each sensor group comprising a plurality of sensors related to each other to some extent) to make a similar determination and transmit the alarm information to the controller 2.
The alarm display signals produced by the alarm display signal producing function are also inputted to the screen display control section 2G for presenting various kinds of indications when a screen image of the display unit 50 is shifted from the initial screen 100 to an alarm list screen or other subsequent screen with manipulation of the operator (as described later).
The failure display control section 2D corresponds to the failure display areas 50Bc (see
The failure presence/absence determining function determines, based on the detected signals (status variable data) from the sensor 40, etc., whether each of the detected signals indicates a failed state. As a determination method, failed states are classified, for example, into failure modes given below:
(1) the case where the status variable data is not stabilized and unstable;
(2) the case where the voltage level of the detected signal is too high or short-circuited to the high voltage side;
(3) the case where the voltage level of the detected signal is too low or short-circuited to the low voltage side;
(4) the case where the current level of the detected signal is too low or the circuit is opened;
(5) the case where the current level of the detected signal is too high or short-circuited to the ground side;
(6) the case where a mechanical response is failed (the difference between a target value and an actually measured value is too large); and
(7) the case where the frequency, the pulse width or the cycle is abnormal;
When any of the above conditions is met, this is determined as indicating the presence of a failure and the failure information is outputted to the failure display signal producing function.
The failure display signal producing function receives the failure information and outputs display signals (failure display signals) for presenting corresponding failure indications to the failure display area 50Bc on the display unit 50. In the failure display area 50Bc, each failure is indicated (in the form of a failure code) using, e.g., the number representing a location where the failure has occurred and the above-mentioned failure mode number. Although details of individual failures are not described here, the failures generally include short-circuiting or disconnection of the sensor 40, etc. or cables connected to them, a communication failure in the communication system, an abnormality of the controller 2 itself, an abnormality/sticking (seizure) in a neutral position of a valve spool, and so on.
As in the alarm display control section 2C, of the above-described two functions, the failure presence/absence determining function may be separately provided outside the controller 2. In other words, each sensor may determine by itself based on the self-monitoring function whether the detected signal is normal or abnormal, and if an abnormality is determined, it may transmit alarm information to the failure display signal producing function of the controller 2. As an alternative, another control unit (sub-controller) may be provided for each sensor (or each sensor group comprising a plurality of sensors related to each other to some extent) to make a similar determination and transmit the failure information to the controller 2.
The failure display signals produced by the failure display signal producing function are also inputted to the screen display control section 2G for presenting various kinds of indications when a screen image of the display unit 50 is shifted from the initial screen 100 to a failure list screen or other subsequent screen with manipulation of the operator (as described later).
The screen display control section 2G has a layout control function for an entire screen of the display unit 50. The screen display control section 2G displays an entire layout (including a portion indicating the status variable data and a portion indicating a frame and a form except for indication itself of an alarm/failure) on the initial screen 100. Also, the screen display control section 2G outputs, to the display unit 50, display control signals corresponding to the keypad operational signal X, a manual snapshot start command signal and an automatic snapshot start command signal which are directly inputted from the signal input processing section 2A, various display signals (described later) from the manual snapshot control section 2E and the automatic snapshot control section 2F, as well as the alarm display signals from the alarm display control section 2C and the failure display signals from the failure display control section 2D, thereby changing over the display such that the screen image is shifted from the initial screen 100 to another screen.
In
In step 60, a detailed information screen 102 of the selected alarm is displayed (see
In step 90, a circuit diagram screen 103 indicating the location where the selected alarm occurs is displayed (see
On the other hand, if the operator manipulates the button 51g of the keypad 51 in the state of the initial screen 100 being displayed in step 10, the determination of step 110 is satisfied via step 20 and the control flow enters an failure-side screen shift mode and proceeds to step 120 in which the screen image is changed to a failure list (List-2) screen 104 indicating a list of the contents of failures occurred at that time (see
In step 150, a detailed information screen 105 of the selected failure is displayed (see
In step 180, a circuit diagram screen 106 indicating the location where the selected failure occurs is displayed (see
Returning to
The intermediate processing section 2Ea executes primary processing of the status variable data. More specifically, the intermediate processing section 2Ea takes in, via the signal input processing section 2A, all the detected signals transmitted from the sensor 40, etc. (or from each unit of the sensor groups or each sub-controller mentioned above) at predetermined intervals, classifies or assorts those data for, e.g., each sensor (or each status variable), and stores or loads the data on the time serial basis.
In accordance with a manual snapshot command signal (signal for indicating an item selected for the manual snapshot function, described in detail later) inputted from the keypad 51 via the signal input processing section 2A, the manual snapshot processing section 2Eb extracts and reads the status variable data corresponding to the command signal from the intermediate processing section 2Ea and produces, as manual snapshot data, the status variable data falling within a predetermined time corresponding to, e.g., a manual snapshot start signal inputted from the keypad 51 via the signal input processing section 2A. The manual snapshot processing section 2Eb previously stores a map of combinations between snapshot items and a plurality of status variables corresponding to each of the formers.
As shown in
Thus, in the manual snapshot processing section 2Eb, the above-described data extracting process is executed while referring to the map shown in
Returning to
In accordance with a playback command signal (signal indicating the manual snapshot data to be played back as a motion picture, described in detail later) inputted from the keypad 51 via the signal input processing section 2A, the playback processing section 2Ed extracts and reads the manual snapshot data corresponding to the command signal from the storage processing section 2Ec and plays back the manual snapshot data, as a motion picture (which may be a still picture instead), in accordance with the command signal (as described in detail later).
The automatic snapshot control section 2F is used to automatically collect various data concentrated in a short period regardless of the operator's intention when an alarm or failure indication is given by the alarm display control section 2C or the failure display control section 2D. The automatic snapshot control section 2F comprises an intermediate processing section 2Fa, an automatic snapshot processing section 2Fb, a storage processing section 2Fc, and a playback processing section 2Fd.
The intermediate processing section 2Fa executes primary processing of the status variable data. More specifically, the intermediate processing section 2Fa takes in, via the signal input processing section 2A, all the detected signals transmitted from the sensor 40, etc. (or from each unit of the sensor groups or each sub-controller mentioned above) at predetermined intervals, classifies or assorts those data for, e.g., each sensor (or each status variable), and stores or loads the data on the time serial basis.
The automatic snapshot processing section 2Fb includes storage means capable of continuously storing data (e.g., the so-called ring buffer which continuously stores data while updating data corresponding to a predetermined time in an overwrite manner). With such storage means, the automatic snapshot processing section 2Fb extracts and reads the status variable data, which has been classified or assorted by the intermediate processing section 2Fa as described above, from the intermediate processing section 2Fa, and it continuously produces automatic snapshot primary data while updating the data in an overwrite manner. The automatic snapshot processing section 2Fb previously stores a map of combinations between alarm/failure items and a plurality of status variables corresponding to each of the formers.
As shown in
Thus, in the automatic snapshot processing section 2Fb, the above-described process of producing the automatic snapshot primary data while updating the data in an overwrite manner is executed while referring to the map shown in
Returning to
In accordance with a playback command signal (signal commanding selection of the alarm/failure to play back corresponding automatic snapshot data, described in detail later) inputted from the keypad 51 via the signal input processing section 2A, the playback processing section 2Fd extracts and reads the automatic snapshot data corresponding to the command signal from the storage processing section 2Fc and plays back the automatic snapshot data, as a motion picture (which may be a still picture instead), in accordance with the command signal (as described in detail later).
In
Returning to
In step 260, the screen display control section 2G changes the screen image to a details/playback selection screen 112 (i.e., a state where a later-described screen 112a or 112b is displayed) for prompting the operator to select a shift to a screen for indicating details of the selected alarm or failure or a shift to a playback screen for playing back the automatic snapshot data which has already been collected and stored at that time (see
In step 280, a detailed information screen of the selected alarm or failure is displayed (though not shown). This detailed information screen is similar to the above-described screen 102 (see
In step 310, a circuit diagram screen indicating the location where the selected alarm or failure occurs is displayed (though not shown). This circuit diagram screen is similar to the above-described screen 103 (see
In the state where the details/playback selection screen 112 is displayed in step 260, if the operator manipulates the “◯” button 51a of the keypad 51 while selecting the “snapshot playback” button (i.e., in the screen 112b of
In step 340, the playback processing section 2Fd displays a motion picture playback screen to play back, in the form of a motion picture, the automatic snapshot data which has already been produced by the automatic snapshot processing section 2Fb and stored in the storage processing section 2Fc in relation to the selected alarm or failure. Though not shown in detail, this motion picture playback screen has an area for indicating the name of the automatic snapshot item (e.g., “coolant overheat alarm”), and an area for indicating changes of each status variable within a certain time. If the operator now manipulates the “x” button 51b of the keypad 51, the determination of step 350 is satisfied and the control flow returns to step 260, whereupon the screen image is returned to the previous screen 112.
On the other hand, if the operator manipulates the “↑” or “↓” button 51d, 51e of the keypad 51 to select the “monitoring/manual snapshot” button 110b and manipulates the “◯” button 51a of the keypad 51 in the state of the menu screen 110 being displayed in step 220, the determination of step 360 is satisfied via step 230 and the control flow enters a manual snapshot-side screen shift mode and proceeds to step 370 in which the screen display control section 2G changes the screen image to a monitoring/playback selection screen 113 (i.e., a state where a later-described screen 113a or 113b is displayed) for prompting the operator to select a shift to a monitoring screen for displaying the current status variable data related to each snap shot item and for producing and recording the manual snapshot data or a shift to a playback screen for playing back the manual snapshot data which has already been collected and stored at that time (see
In step 390, the screen display control section 2G changes the screen image to a manual snapshot item screen 114 (see
In step 410, the status variable data corresponding to the selected engine item 114A and snapshot item 114B are taken in. More specifically, as described above, the manual snapshot processing section 2Eb extracts and reads, from the intermediate processing section 2Ea, the status variable data corresponding to the selected items (e.g., the data representing “atmospheric temperature”, “air temperature at radiator front surface”, “radiator outlet temperature”, “coolant temperature in upper manifold”, “inlet pressure of hydraulic motor for cooler fan”, and “coolant pressure (coolant pump delivery pressure/upper manifold pressure)” when the heat balance is selected), and then outputs the read status variable data to the screen display control section 2G. The screen display control section 2G changes the screen image to a monitoring screen 115 on which changes of the current status variable data are indicated (see
Herein, the most important feature of this embodiment resides in that the manual snapshot processing section 2Eb compares each of the status variables or a value computed through predetermined arithmetic processing based on a plurality of status variables, which are extracted and read from the intermediate processing section 2Ea (namely, the status variables displayed on the monitoring screen 115) in relation to the selected snapshot item, with a corresponding predetermined reference value range (i.e., a reference value range set and stored in advance), thereby determining whether a part corresponding to each status variable or the computed value is failed. If any failure is determined, the manual snapshot processing section 2Eb outputs a display signal for displaying the failed part (i.e., a failed part display signal) to the screen display control section 2G, whereupon the screen display control section 2G displays a corresponding screen. Such a part failure determination/display process will be described below, by way of example, in connection with the case of selecting “heat balance” as the snapshot item.
(1) Failure Determination/Display Process for Radiator
Referring to
If the calculated temperature difference ΔTrad is not larger than the first reference value ΔTref1, this is regarded as meaning that a failure (such as clogging) does not occur in the radiator. Hence the determination of step 530 is not satisfied and the control flow proceeds to step 540. In step 540, the manual snapshot processing section 2Eb outputs an ordinary display signal representing no failure in the radiator (or the status variables “atmospheric temperature” and “coolant temperature in manifold” related to the radiator), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for each of “atmospheric temperature” and “coolant temperature in manifold” in ordinary color (e.g., light blue).
If the temperature difference ΔTrad is larger than the first reference value ΔTref1 in step 530, the determination of step 530 is satisfied and the control flow proceeds to step 550. In step 550, a predetermined second reference value ΔTref2 (ΔTref2>ΔTref1) is read out from the internal memory, for example, and whether the calculated temperature difference ΔTrad is larger than the second reference value ΔTref2 is determined. If the calculated temperature difference ΔTrad is not larger than the predetermined second reference value ΔTref2 (i.e., ΔTref2≧ΔTref1>Tref1), this is regarded as meaning that a failure occurs to some extent in the radiator. Hence the determination of step 550 is not satisfied and the control flow proceeds to step 560. In step 560, the manual snapshot processing section 2Eb outputs a first-stage failure display signal representing some extent of a failure in the radiator (or the status variables “atmospheric temperature” and “coolant temperature in manifold” related to the radiator), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for each of “atmospheric temperature” and “coolant temperature in manifold” in different color, e.g., yellow (display color for a failure of first stage).
On the other hand, if the temperature difference ΔTrad is larger than the predetermined second reference value ΔTref2, this is regarded as meaning that a failure occurs in the radiator. Hence the determination of step 550 is satisfied and the control flow proceeds to step 570. In step 570, the manual snapshot processing section 2Eb outputs a second-stage failure display signal representing a failure in the radiator (or the status variables “atmospheric temperature” and “coolant temperature in manifold” related to the radiator), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for each of “atmospheric temperature” and “coolant temperature in manifold” in different color, e.g., red (display color for a failure of second stage).
If each of steps 540, 560 and 570 is completed, the control flow proceeds to step 580 in which it is determined whether the monitoring screen 115 is changed to another screen. If changed, the determination of step 580 is satisfied and the failure determination/display process for the radiator is brought to an end. On the other hand, if the monitoring screen 115 is not changed to another screen, the determination of step 580 is not satisfied and the control flow returns to step 510, followed by repeating the same procedures as those described above.
(2) Failure Determination/Display Process for Hydraulic Motor for Cooling Fan
Referring to
If the inlet pressure Pfun of the hydraulic motor for the cooling fan is not higher than the predetermined first reference value Pfun_ref1, this is regarded as meaning that no failure occurs in the hydraulic motor for the cooling fan. Hence the determination of step 620 is not satisfied and the control flow proceeds to step 630. In step 630, the manual snapshot processing section 2Eb outputs an ordinary display signal representing no failure in the hydraulic motor for the cooling fan (or the status variable “inlet pressure of hydraulic motor for cooling fan” related to the hydraulic motor for the cooling fan), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for “inlet pressure of hydraulic motor for cooling fan” in ordinary color (e.g., light blue).
If the inlet pressure Pfun of the hydraulic motor for the cooling fan is higher than the predetermined first reference value Pfun_ref1 in step 620, the determination of step 620 is not satisfied and the control flow proceeds to step 640. In step 640, a predetermined second reference value Pfun_ref2 (Pfun_ref2>Pfun_ref1) is read out from the internal memory, for example, and whether the inlet pressure Pfun of the hydraulic motor for the cooling fan is higher than the predetermined second reference value Pfun_ref2 is determined. If the inlet pressure Pfun of the hydraulic motor for the cooling fan is not higher than the predetermined second reference value Pfun_ref2 (i.e., Pfun_ref2≧Pfun>Pfun_ref1), this is regarded as meaning that a failure occurs to some extent in the hydraulic motor for the cooling fan. Hence the determination of step 640 is not satisfied and the control flow proceeds to step 650. In step 650, the manual snapshot processing section 2Eb outputs a first-stage failure display signal representing some extent of a failure in the hydraulic motor for the cooling fan (or the status variable “inlet pressure of hydraulic motor for cooling fan” related to the hydraulic motor for the cooling fan), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for “inlet pressure of hydraulic motor for cooling fan” in different color, e.g., yellow (display color for a failure of first stage).
On the other hand, if the inlet pressure Pfun of the hydraulic motor for the cooling fan is higher than the predetermined second reference value Pfun_ref2, this is regarded as meaning that a failure occurs in the hydraulic motor for the cooling fan. Hence the determination of step 640 is satisfied and the control flow proceeds to step 660. In step 660, the manual snapshot processing section 2Eb outputs a second-stage failure display signal representing a failure in the hydraulic motor for the cooling fan (or the status variable “inlet pressure of hydraulic motor for cooling fan” related to the hydraulic motor for the cooling fan), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for “inlet pressure of hydraulic motor for cooling fan” in different color, e.g., red (display color for a failure of second stage).
If each of steps 630, 650 and 660 is completed, the control flow proceeds to step 670 in which it is determined whether the monitoring screen 115 is changed to another screen. If changed, the determination of step 670 is satisfied and the failure determination/display process for the hydraulic motor for the cooling fan is brought to an end. On the other hand, if the monitoring screen 115 is not changed to another screen, the determination of step 670 is not satisfied and the control flow returns to step 610, followed by repeating the same procedures as those described above.
(3) Failure Determination/Display Process for Coolant Pump and Piping System
Referring to
If the coolant pressure Prad is not higher than the predetermined first reference value Prad_ref1, this is regarded as meaning that no failure occurs in the coolant pump. Hence the determination of step 720 is not satisfied and the control flow proceeds to step 730. In step 730, the manual snapshot processing section 2Eb outputs an ordinary display signal representing no failure in the coolant pump and the piping system (or the status variable “coolant pressure” related to the coolant pump and the piping system), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for “coolant pressure” in ordinary color (e.g., light blue).
If the coolant pressure Prad is higher than the predetermined first reference value Prad_ref1 in step 720, the determination of step 720 is not satisfied and the control flow proceeds to step 740. In step 740, a predetermined second reference value Prad_ref2 (Prad_ref2>Prad_ref1) is read out from the internal memory, for example, and whether the coolant pressure Prad is higher than the predetermined second reference value Prad_ref2 is determined. If the coolant pressure Prad is not higher than the predetermined second reference value Pfun_ref2 (i.e., Prad_ref2≧Prad>Prad_ref1), this is regarded as meaning that a failure occurs to some extent in the coolant pump and the piping system. Hence the determination of step 740 is not satisfied and the control flow proceeds to step 750. In step 750, the manual snapshot processing section 2Eb outputs a first-stage failure display signal representing some extent of a failure in the coolant pump and the piping system (or the status variable “coolant pressure” related to the coolant pump and the piping system), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for “coolant pressure” in different color, e.g., yellow (display color for a failure of first stage).
On the other hand, if the coolant pressure Prad is higher than the predetermined second reference value Prad_ref2, this is regarded as meaning that a failure occurs in the coolant pump and the piping system. Hence the determination of step 740 is satisfied and the control flow proceeds to step 760. In step 760, the manual snapshot processing section 2Eb outputs a second-stage failure display signal representing a failure in the coolant pump and the piping system (or the status variable “coolant pressure” related to the coolant pump and the piping system), and the screen display control section 2G displays the background area 115Ba of the status variable display area 115B for “coolant pressure” in different color, e.g., red (display color for a failure of second stage).
If each of steps 730, 750 and 760 is completed, the control flow proceeds to step 770 in which it is determined whether the monitoring screen 115 is changed to another screen. If changed, the determination of step 770 is satisfied and the failure determination/display process for the coolant pump and the piping system is brought to an end. On the other hand, if the monitoring screen 115 is not changed to another screen, the determination of step 770 is not satisfied and the control flow returns to step 710, followed by repeating the same procedures as those described above.
As described above, the monitoring screen 115 displays not only changes of the status variable data related to the snapshot item selected by the operator, but also the presence or absence of a failure in each status variable and the corresponding part in a stepwise manner using different colors for display of the background area 115Ba of the status variable display area 115B.
Returning to
If the operator manipulates the “x” button 51b of the keypad 51 in such a state, the screen image is returned to the previous screen 115. On the other hand, if the operator manipulates the “◯” button 51a of the keypad 51, a circuit diagram screen 117 indicating the location where the failure occurs is displayed (see
Returning to
In step 440, the manual snapshot start signal is inputted to the manual snapshot processing section 2Eb from the signal input processing section 2A, whereupon the manual snapshot processing section 2Eb extracts and reads, from the intermediate processing section 2Ea, the status variable data corresponding to the above select manipulation, which falls within a predetermined time (e.g., preset ranges before and after the time of issuance of the manual snapshot command, the preset ranges may be settable in accordance with a command from the operator), thereby producing the manual snapshot data. Thereafter, the control flow proceeds to step 450 in which the storage processing section 2Ec records or loads the manual snapshot data produced by the manual snapshot processing section 2Eb. During steps 440 and 450, the screen display control section 2G displays the appropriate corresponding screen. After the completion of step 450, the control flow returns to step 410 in which the screen 115 is displayed.
In the state where the monitoring/playback selection screen 113 is displayed in step 370, if the operator manipulates the “◯” button 51a of the keypad 51 while selecting the “monitoring/recording/playback” button (see the screen 113b of
In step 470, the screen display control section 2G changes the screen image to a manual snapshot data list screen 118 (see
In step 490, the playback processing section 2Ed displays a motion picture playback screen 119 to play back, in the form of a motion picture, the selected manual snapshot data (see
The status variable display area 119B of the motion picture playback screen 119 has the same layout as that of the above-described status variable display area 115B shown in
Further, as shown in
Returning to
Although a detailed description is omitted here, when the “maintenance history list” button 110c is manipulated, the screen display control section 2G performs a screen shift to a maintenance history list display screen (not shown). More specifically, whenever maintenance work, such as greasing to various parts, oil change, filter change, grease refilling, element change, coolant change, and working oil change, has been so far performed for the relevant machine, maintenance history data has been inputted by the worker or the operator and separately stored as maintenance history data in the storage means. The maintenance history list display screen is used to read and display the stored maintenance history. For example, the maintenance history list display screen indicates the maintenance items, the time interval (for change) preset for each item, and the time lapsed from the last actual change to the current time together.
Although a detailed description is omitted here, when the “life” button 110d is manipulated, the screen display control section 2G displays a life data display screen for indicating the accumulative operation time of each part from the start of operation of the machine, which has been collected by an operation time collecting function (not shown) of the controller 2 for each part.
Although a detailed description is omitted here, when the “machine information” button 110e is manipulated, the screen display control section 2G displays a machine information (property) data display screen for indicating specific information of the machine itself, such as the machine model number, the machine body number, the name of the controller, the name of software, and the version.
Although a detailed description is omitted here, when the “various settings” button 110f is manipulated, the screen display control section 2G displays a various-settings screen for setting the maintenance period, the on/off condition of each alarm, and others.
With this embodiment constructed as described above, for example, when the operator manipulates the keypad 51 so as to display the snapshot item screen 114 (see
Moreover, for example, in the case of the operator intuitively perceiving a sign indicating an abnormality, e.g., a drop of engine output, during the operation, when the operator manipulates the keypad 51 to display the monitoring screen 115 and enters a recording command, the status variable data related to the snapshot item and falling within the predetermined time (i.e., the manual snapshot data) is produced and store by the manual snapshot control section 2E. Thereafter, when the operator manipulates the keypad 51 to display the manual snapshot data list screen 118 and selects the manual snapshot data, the selected manual snapshot data is read by the manual snapshot control section 2E and is played back to be displayed on the motion picture playback screen 119 by the screen display control section 2G. On that occasion, the manual snapshot control section 2E compares each of the status variables or a value computed based on a plurality of status variables, which are contained in the read status variable data (namely, the status variables displayed on the motion picture playback screen 119), with each of a plurality of corresponding predetermined reference values. If the status variable or the computed value is outside a predetermined reference value range, a failure of a corresponding part is determined in a stepwise manner. Further, if a failure is determined, the background area of the status variable display area 119B related to the failed part is displayed in a stepwise manner using different colors, e.g., yellow and red. When the operator selects the status variable display area 119B, the detailed information screen 116 for the corresponding failure and the circuit diagram drawing 117 for the failed part are displayed.
Thus, according to this embodiment, the status variable data related to the snapshot item or the stored manual snapshot data is displayed on the display unit 50, and whether a part corresponding to each status variable is failed is determined. If a failure is determined, the failed part or the related status variable is displayed on the display unit 50. Therefore, the operator can find an abnormality before it actually occurs. Also, any serviceman can easily specify the failed part regardless of experiences and skills of individual servicemen. As a result, it is possible to cut the operation suspended time of the hydraulic excavator 1, and to increase productivity.
Further, this embodiment can provide the following advantages.
(1) Advantage of Reducing Burden on Operation with Simplification in Display of Initial Screen
According to this embodiment, the sensor 40, etc. detect the status variables related to the operating state or the ambient environment, and in response to the detected signals, the basic data display control section 2B of the controller 2 outputs the basic data display signals required for the initial screen 100 to the display unit 50, thereby displaying those signals in the basic data display area 50A. On the other hand, in accordance with alarm information related to the status variables detected by the sensor 40, etc., the alarm display control section 2C outputs the alarm display signals to the display unit 50, thereby displaying alarms in the alarm display areas 50Ba and 50Bb. Further, in accordance with failure information from the sensor 40, etc., the failure display control section 2D outputs the failure display signal to the display unit 50, thereby displaying a failure in the failure display area 50Bc.
Thus, on the initial screen 100 of the display unit 50, unless the operator specifically instructs a screen shift during the machine operation, only the least necessary basic data is displayed in the basic data display area 50A without displaying other data, while the alarm/failure is displayed in the alarm/failure display area 50B. As a result, abnormal information of the construction machine can be effectively presented with the least necessary data by displaying the data in such a manner as avoiding the operator from feeling psychological burden and discomfort over an allowable level.
(2) Advantage with Automatic Snapshot Function
According to this embodiment, when the alarm or the failure is displayed in the alarm/failure display area 50B of the initial screen 100, a portion of the status variable data related to the alarm or the failure, which falls within the predetermined time, is automatically acquired and stored by the automatic snapshot control section 2F of the controller 2. When the operator manipulates the keypad 51 later in the state of the alarm/failure list screen 111 being displayed, the playback processing section 2Fd outputs the playback display signal and displays the motion picture playback screen.
Thus, from the alarm/failure display presented in the least necessary way on the initial screen 100, the operator is able to confirm details of the alarm/failure, as required, for assistance to failure diagnosis. In particular, in the ordinary mode, the alarm/failure-related status variables falling within the predetermined time are automatically acquired with no need of particular manipulation by the operator, and can be played back later for display. Therefore, the location and details of an abnormality in the construction machine can be precisely presented without including useless extra information. As a result, it is possible to minimize the suspension time when an abnormality occurs in the construction machine, and to increase productivity.
(3) Advantage with Maintenance History Display
A construction machine, such as a large-sized hydraulic excavator, used for excavation of earth and stones in a very wide worksite or the like is continuously operated, and only an operator takes turns in operation of the machine per predetermined time. In the event of any alarm or failure, for example, the succeeding operator often wants to know what maintenance has been performed during the work by the preceding operator. To be adapted for such a situation, in this embodiment, when the operator manipulates the “maintenance history list” button 110c of the menu screen 110 upon looking at the displayed alarm or failure, a list of maintenance history data is displayed on the maintenance history list display screen.
Thus, from the alarm/failure display presented in the least necessary way on the initial screen 100, the operator is able to confirm maintenance situations, as required, for assistance to failure diagnosis.
While the above embodiment has been described as using, as one example of display means, the display unit 50 disposed inside the cab 14 of the hydraulic excavator 1, the present invention is not limited to such an example. Alternatively, the display means may be a PC terminal capable of receiving data downloaded via communication means, e.g., wires, radio or the Internet.
Further, while the above description has been made in connection with the hydraulic excavator 1 as an example of the construction machine, an application field of the present invention is not limited to the hydraulic excavator. The present invention is also applicable to other types of construction machines, such as a crawler crane and a wheel loader, and can provide similar advantages in those applications.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2004-333101 | Nov 2004 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP05/19767 | 10/27/2005 | WO | 12/29/2006 |
