Embodiments of the present invention are now described with reference to the accompanying drawings.
As shown in
The controller 10 comprises a display unit 11, an input unit 12, a CPU 13, a ROM 14, a RAM 15 and a memory unit 16, all of which are connected via a bus 19. This controller 10 is connected to the first acceleration sensor 4 and the second acceleration sensor 6 via an A/D converter 17, and is also connected to the vibration generator 2 via a D/A converter 18. The controller may be composed of an information processing apparatus, e.g., a personal computer.
The display unit 11 is composed of a liquid crystal display monitor, CRT monitor or the like, and the input unit 12 is composed of a mouse, input keys, a touch panel or the like. The CPU 13 controls the operation of the vibration generator 2 by execution of a vibration test program, and performs a vibration test on the specimen P as described below. The ROM 14 stores transport conditions (e.g., vibration acceleration, transport time, vibration frequencies, etc., during actual transportation) corresponding to various transport routes, a vibration test program executed by the CPU 13, and the like. The RAM 15 stores temporary data which is created during execution of the vibration test program.
The memory unit 16 stores a variety of information. Such information includes vibration data previously measured for the specimen P in each of the various transport routes, transfer functions for reproducing transported states, information input from the input unit 12, detection information from the first acceleration sensor 4 and second acceleration sensor 6, and calculation information from the CPU 13.
A description is next given of a method for performing a vibration test on the specimen P using the vibration test apparatus 1 described above. The flowchart of
(1) Test Specification Setting Step (Step S10)
The test specification setting step is explained referring to the flowchart shown in
A specimen P is first mounted on the vibrating table 2a (Step S11). Examples of specimens P include transported products, such as precision machines and the like housed within containers, such as corrugated boards and the like, together with cushioning materials such as cellular materials, paper, wood, etc. In view of the transported state during actual transportation, the specimen P is preferably mounted so as to enable a vibration test that takes into consideration non-linearity in vibration transfer. For example, when stacked products (in a vertically stacked state) are transported during actual transportation, a plurality of specimens P may be stacked on the vibrating table 2a in the vibration test. In addition to the event of transporting stacked products, non-linearity in vibration transfer may occur, for example, when the transported products vibrate from rattling or hitting, or when the transported products are fluid such as liquids.
A user is then prompted to enter an actual transport route via the input unit 12 of the controller 10, so as to determine a transport scenario representing the transport conditions for the entire transport route (Step S12). The CPU 13 causes the display unit 11 to display a screen for setting the test specifications, for example, as shown in
The scenario setting screen shown in
Where modification(s) have to be made to the transport conditions for the selected scenario name, the user may press the “Edit” button on the scenario setting screen shown in
In actual transportation, it is common to use more than one transportation means, and there are few cases of transporting via a single transportation means. Therefore, after reading the selected scenario, the CPU 13 displays the scenario setting screen shown in
The CPU 13 subsequently searches the memory unit 16 based on the determined transportation scenario to acquire vibration data corresponding to each subscenario of the transportation scenario, and creates vibration data for the entire transport scenario by combining these subscenarios, thereby determining reference vibration conditions based on the transport conditions during actual transportation (Step S13).
Vibration data stored in the memory unit 16 can be derived by, for example, using a vibrograph to actually measure vibration acceleration of the surface on which transported products are mounted (e.g., the cargo bed of a truck) during actual transportation under the transport conditions of each scenario name, for example, as displayed in the scenario setting screen of
The CPU 13 then prompts the user to enter a variation coefficient, an allowable damage probability, and a desired damage probability on the test specification setting screen shown in
The variation coefficient is an index of variation in the durability of each transported product, which is, for example, set to any one of 120%, 60% or 30% by the user selecting from the three levels, i.e., high, medium or low. The input of a variation coefficient may be done by storing a previously measured variation coefficient for each kind of transported product (e.g., displays, DVDs, bags-in-boxes, etc.) in the memory unit 16, so that the corresponding variation coefficient is read and set by the user selecting the kind of products.
The allowable damage probability is an index of the damage probability that is acceptable during actual transportation. The allowable damage probability is set to a small value when the transported products are expensive or can cause danger when broken, and is set to a large value when they are inexpensive or readily replaceable.
The desired damage probability is an index of the probability of the specimen P being broken by a vibration test when the damage probability of the specimen P is substantially equal to the allowable damage probability. The desired damage probability can be set to a small value when there is a large quantity of specimens P, and is set to a large value when there is a small quantity of specimens P.
In the vibration test method of this embodiment, an accumulated fatigue value XR resulting from the transport conditions during the actual transportation is multiplied by a safety factor S, so as to evaluate a reference accumulated fatigue value XT(namely, XT=S×XR) which is imparted to the specimen, in order to maintain a high testing accuracy even though the test time is shorter and the quantity of specimens is smaller than those during the actual transportation. This allows the vibration test to be performed under optimal conditions, so as to reduce the incidence of customer complaints in the market while preventing overpackaging to reduce costs.
Assuming that the probability distribution of durabilities of the transported products is a Weibull distribution, the input variation coefficient η, allowable damage probability PM and desired damage probability PT are represented by the mathematical expressions (1), (2) and (3), respectively, shown below:
η=[{Γ(1+(2/α))/{Γ(1+(1/α))}2}−1]1/2 (1)
P
M=1−exp{−(xR/β)α} (2)
P
T=1−exp{−(xT/β)α} (3)
wherein each α and β are the shape parameter and scale parameter, respectively, of the Weibull distribution.
Using these expressions, the CPU 13 calculates a safety factor S based on the input variation coefficient η, allowable damage probability PM and desired damage probability PT, and displays the safety factor on the test specification setting screen of
The number N of specimens P can also be input in the test specification setting screen of
D=(1−PT)N (4)
In this embodiment, the risk percentage of the test D is determined based on the input desired damage probability PT and number N of specimens. As is clear from the expression (4), however, when a preferable value has been preset for the risk percentage of the test D, the desired damage probability PT can be determined by inputting the number N. In other words, the safety factor S can also be calculated by assuming an input of the number N to be an input of the desired damage probability PT.
The safety factor calculation described above may also be performed in the reference value attainment step (Step S20) described below, instead of the test specification setting step (Step S10) as in this embodiment.
(2) Reference Value Attainment Step (Step S20)
The reference value attainment step is explained referring to the flowchart shown in
The user selects whether non-linearity is taken into consideration in the actual test or not (Step S21). The selection can be done on a preliminary test setting screen as shown in
In this embodiment, the amplitude peak value is used as an index representing the amplitude level of the transported products, but other indices of amplitude level may also be used, such as root mean square (RMS) and the like.
Conversely, if the user takes non-linearity into consideration, he or she selects whether the transported state will be reproduced or not (Step S23). On the preliminary test setting screen shown in
If the transported state is reproduced at Step S23, the user subsequently chooses whether a transfer function representing non-linearity is selected from the preset transfer functions or is derived by actual measurement (Step S25). When selecting a transfer function for reproducing the stacked state from the variety of preset transfer functions, the user clicks the “Select stacked-state reproducing transfer function” column on the preliminary test setting screen of
If the user chooses to perform actual measurement at Step S25, specimens P are stacked on the vibrating table 2a, and the user clicks the “Obtain stacked-state reproducing transfer function” column on the preliminary test setting screen of
One example of the accumulated fatigue value calculation method at Step S22 comprises determining PSDs based on time series data of a given period which is detected by the second acceleration sensor 6 attached to each specimen P, and calculating an accumulated fatigue value based on the PSDs. The accumulated fatigue value calculation based on PSDs may be performed, for example, in accordance with the method disclosed in Japanese Unexamined Publication No. 2005-181195.
In the accumulated fatigue value calculation method, the accumulated fatigue value corresponding to the entire transport scenario is calculated using an accumulated fatigue value calculated for each subscenario. For example, in the case of the transport scenario shown in
When determining the accumulated fatigue value during actual transportation, variation in the accumulated fatigue value expected in the market may further be considered with respect to the accumulated fatigue value XR determined as above. For example, let XR be an accumulated fatigue value having a reliability of 3δ (99.87%), then XR=(1+3ηXR)μXR, wherein η is the variation coefficient, and μXR is the mean accumulated fatigue value.
After determining the accumulated fatigue value of the transported products during actual transportation at Step S22, this accumulated fatigue value is multiplied by the safety factor calculated at Step S14, thereby determining the reference accumulated fatigue value (Step S29).
In obtaining the amplitude peak value at Step S22, the maximum amplitude peak value of the transported products of all the subscenarios may be used as the amplitude peak value for the entire transport scenario.
(3) Test Condition Determination Step (Step S30)
The test condition determination step is explained referring to the flowchart shown in
The user inputs a desired vibration time and an allowable amplification factor in the test (Step S31). The inputs can be made on an actual test setting screen as shown in
The desired vibration time is the time during which the user wishes to vibrate the specimen P in the test. The allowable amplification factor is the maximum amplification factor that is permitted for the amplitude peak value of the transported products during actual vibration. In general, reducing the desired vibration time allows the test to be terminated in a short time, resulting in improved test efficiency. However, it inevitably increases the amplification factor of the amplitude peak value of the transported products, resulting in a higher possibility of exceeding the allowable amplification factor. The increase in the amplification factor causes a greater difference between the level of vibration during actual vibration and that during the test, which may result in reduced testing accuracy.
The CPU 13 determines test vibration conditions and a test time for an actual test based on the input desired vibration time, allowable amplification factor, and priority order (Step S33). More specifically, an accumulated fatigue rate V(XT) of the specimen P is calculated in accordance with the mathematical expression (5) shown below, based on PSD values (PSD0) which have been determined based on the acceleration detection data from the second acceleration sensor 6 for detecting the vibration of the specimen P.
The reference accumulation fatigue XT(fi) for each frequency band is subsequently divided by the desired vibration time T, and the result is defined as the reference accumulated fatigue rate (XT(fi)/T). The CPU 13 controls the operation of the vibration generator 2 so that the aforementioned accumulated fatigue rate satisfies the reference accumulated fatigue rate, and the amplitude peak value detected by the second acceleration sensor 6 does not exceed the allowable amplification factor. This allows the test to be terminated in the desired vibration time T. Note that a safety function is preferably provided for controlling the operation of the vibration generator 2 so that the rating of the vibration generator 2 is not exceeded.
If non-linearity in vibration transfer is not taken into consideration, the detection data obtained from the first acceleration sensor 4 attached to the vibrating table 2a may be used as detection data for use in calculating the accumulated fatigue rate of the specimen P. When a plurality of second acceleration sensors 6 are attached to each of multiple stacked specimens P, the operation of the vibration generator 2 is preferably controlled so that the slowest accumulated fatigue rate satisfies the reference accumulated fatigue rate. This allows the test to be terminated in the desired vibration time T.
That is, when the input desired vibration time and allowable amplification factor are compatible, the desired vibration time is set as a test time without modification, and the aforementioned pattern of the CPU 13 controlling the operation of the vibration generator 2 is set as test vibration conditions.
In contrast, when the amplitude peak value detected by the second acceleration sensor 6 has exceeded the allowable amplification factor during the CPU 13 controlled operation of the vibration generator 2, the CPU 13 recognizes the priority order input on the actual test setting screen, and continues, if priority is placed on the desired vibration time, controlling the operation of the vibration generator 2, and displays the actual amplitude amplification factor on the display unit 11. Conversely, if priority is placed on the allowable amplification factor, the CPU 13 controls the operation of the vibration generator 2 so that the detected amplitude peak value does not exceed the allowable amplification factor, and displays on the display unit 11 a test time which is calculated based on the accumulated fatigue rate obtained in this case.
As described above, when the input desired vibration time and allowable amplification factor are incompatible, the CPU 13 operates to satisfy one of the two conditions based on the priority order, and displays a modified value of the other on the display unit 11. The user checks the modified value, and if the value is acceptable, he or she verifies the value by using the input unit 12, allowing the test vibration conditions and test time in the test to be lastly determined. Consequently, it is possible to maintain a high testing accuracy while attaining optimal test conditions which allow the test time to be shortened.
If the detected amplitude peak value has exceeded the allowable amplification factor with a priority being placed on the allowable amplification factor, the CPU 13 reduces the reference accumulated fatigue rate in controlling the operation of the vibration generator 2. However, the test time increases if the reference accumulated fatigue rate is kept low, and therefore once the level of the detected amplitude peak value has become smaller, it is preferable to increase the reference accumulated fatigue rate again.
(4) Vibration-Imparting Step (Step S40)
The vibration-imparting step is explained referring to the flowchart shown in
After the specimen P has been mounted on the vibrating table 2a, an actual vibration test is started based on the determined test vibration conditions and test time (Step S41). When specimens P are transported, for example, in a stacked state, the actual test can similarly be performed with the specimens P being stacked.
The second acceleration sensor 6 (which may also be substituted by the first acceleration sensor 4 where possible) detects the vibration acceleration of the specimen P during the actual vibration test. On the basis of this detection, the CPU 13 calculates accumulated fatigue rates of the specimen P in real time in accordance with the aforementioned mathematical expression (5). The CPU 13 subsequently determines the presence of damage to the specimen based on the amount of change in the accumulated fatigue rate (Step S42). For example, when a change in the accumulated fatigue rate has exceeded a threshold value, the CPU 13 determines that the specimen P has been damaged, and provides a warning indication on the display unit 11 while calculating an elapsed time and accumulated fatigue values until that moment, accumulated fatigue rates and PSDs before and after that moment, etc., and stores them in the memory unit 16 as damage information (Step S43). The CPU 13 then terminates the vibration test after the elapse of a given period of time.
In contrast, when determining that the specimen has not been damaged at Step S42, the CPU 13 moves onto Step S44, where it terminates the vibration test when the test termination time has come, or repeats Step S42 and thereafter when the test termination time has yet to come.
In this embodiment, the presence of damage to the specimen P is determined based on the amount of change in the accumulated fatigue rate; however, any other indices may be used if they are concerned with the vibration transfer apparatus based upon the vibration detection values of specimens. For example, the presence of damage to the specimen P may be determined based on the amount of change in the PSD, RMS or the like. The presence of specimen damage may also be determined based on the rate of change of such an index, instead of the amount of change.
Although the embodiment describes the specimens as being transported products, the present invention can also be applied to devices and components installed in equipment subjected to vibration, such as transportation means.
Number | Date | Country | Kind |
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2006-116890 | Apr 2006 | JP | national |