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Source: Huanqiu.com

[Global Network Technology Report Reporter Lin Mengxue]Accompanied by the roar of machines on the production line and rows of efficiently operating robotic arms waving... Such scenes are not uncommon when you walk into a digital factory workshop.

With the deepening of intelligent manufacturing, the application of robots is also accelerating. According to data released by the 2023 World Robot Conference, in 2022, my country's industrial robot installations accounted for more than 50% of the world's total, ranking first in the world's industrial robot market, and the density of manufacturing robots reached 392 per 10,000 workers.

However, in a high-speed automated factory, with a large number of robots working together, equipment failures will cause production interruptions and subsequent repairs, which will generate a lot of cost issues. Therefore, the operating efficiency and stability of equipment are crucial to the production operations of enterprises.

So, how can we reduce the cost losses caused by equipment failure?

Current Sensing+Intelligent analysis algorithm“Diagnose and diagnose”, workshop losses can be controlled

Entering Guangzhou Futaba Auto Parts Co., Ltd., the reporter saw a digital system that can promptly diagnose and diagnose the robots in the workshop - Hitachi Industrial Equipment Fault Prediction Solution.

Li Lingling, senior sales manager of the South China Solutions Sales Department of the Guangzhou Branch of Hitachi Solutions (China) Co., Ltd., who is in charge of the project, said, "This system mainly uses current sensing technology and intelligent analysis algorithms to provide fault warnings for robot faults. As you can see on the robot arm, we attach an external sensor to the wire, which collects motor current data and transmits it to the industrial computer. Our core algorithm is deployed in the industrial computer, which analyzes the collected data through the algorithm, displays it on the server, and then makes the data into a three-dimensional waterfall chart."

"Compared with the losses caused by equipment failure in the previous year, it is expected that most factories will be able to recover the cost of system investment in about one and a half years by using the fault prediction system," said Li Lingling.

Break down brand and model barriers, and eliminate obstacles in data analysis and processing

Under the wave of digital reform, the factory's production model has undergone significant changes. The production site has achieved a high degree of automation, and many robots work together seamlessly to complete complex tasks that previously required a lot of manual participation. In the past, in production workshops, automated equipment relied on manual inspection, but with more and more equipment and more and more complex procedures, it was difficult for manual capabilities to fully cover the entire process, efficiency was difficult to guarantee, and misjudgment was prone to occur.

Gu Fengqun, deputy general manager of the South China Solutions Sales Department of Hitachi Solutions (China) Co., Ltd. Guangzhou Branch, also mentioned that "many factory robot status records rely on manual entry, which is easy to lose and difficult to find."

In Gu Fengqun's view, it is important to manage robots and early signs of failure. "If one of the robots fails, the entire production line may be paralyzed."

In addition, in the actual scenarios of industrial production, robots of multiple models, brands and categories are used in a mixed manner, and there is no unified data standard and basis.

So, how to manage robots while solving the problem of inconsistency in robot data?

Hitachi's industrial equipment fault prediction and diagnosis solution is handled as follows: "We have developed a non-destructive, fast and universal external current sensing method, which overcomes the barriers between robots and equipment of different brands, and uses our algorithm for analysis to achieve early warning." said Yang Zhe, the project's technical director.

Based on the IoT platform built on Hitachi's DSC/IoT platform, the industrial equipment fault prediction diagnosis solution supports multiple data analysis platforms, is easy to customize and develop, and is compatible with multiple brands and models of robots for data analysis and fault warning.

"Not only robotic arms, in fact, we can predict faults for any motor-driven product in the factory," added Gu Fengqun.

The demand for intelligent management of industrial equipment is growing, and the market for fault prediction is promising

In the wave of digital reform, industrial equipment management is closely related to the improvement of production efficiency, the guarantee of product quality, the optimization of cost control, the guarantee of safe production and the promotion of sustainable development. Therefore, the implementation of effective equipment management strategies has become an indispensable part of the manufacturing enterprises to stabilize and enhance their market competitiveness.

The maintenance cost of industrial equipment accounts for the bulk of enterprise operations and maintenance. Therefore, the market space for fault prediction, which can proactively identify the risks of equipment failures and change the passive maintenance model, is increasing year by year.

Hiroaki Yoshie, general manager of Hitachi Solutions (China) Co., Ltd. Guangzhou Branch, believes that "the installed capacity and ownership of robots in the Chinese market are the highest, but the longer the equipment is used, the more likely it is to have problems."

Yao Kaipeng, chief researcher of the Industrial Technology Research Department of Hitachi China Research Institute, believes that deploying a pre-diagnosis system for industrial equipment is very urgent for the manufacturing industry, which is facing increasing competitive pressure. "The manufacturing industry is becoming more and more competitive and has strict cost control. Our pre-diagnosis solution is completely locally produced, with low deployment costs and obvious effects, which can alleviate the operation and maintenance pressure of manufacturing companies."

"Hitachi is very optimistic about the fault prediction market. About two years ago, our fault prediction products were officially launched into the market. After two years of product sales promotion and anticipation for the fault prediction market, we hope to expand our fault prediction sales in China to seven times the current level," said Yoshie Hiroaki.