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研究生: 胡博期
Hu, Po-Chi
論文名稱: 嵌入式加工系統遠程集中化診斷維修之研究
Study on Embedded Manufacture System Remote Central e-diagnostics and e-maintenance
指導教授: 邵揮洲
Shaw, Heiu- Jou
學位類別: 碩士
Master
系所名稱: 工學院 - 系統及船舶機電工程學系
Department of Systems and Naval Mechatronic Engineering
論文出版年: 2005
畢業學年度: 93
語文別: 中文
論文頁數: 162
中文關鍵詞: 案例式推論方法故障診斷故障模式解析方法貝氏集合理論
外文關鍵詞: Bayesian Set Theorem, Case-based Reasoning, Fault Diagnosis, Failure Model Effects Analysis
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  •   近年來隨著機械製造技術的進步,因此機械功能性也更顯複雜,對於操作人員而言,擁有高效率的監控與維護的平台才能即時處理機械的突發狀況。以往機械單元若發生故障時,往往必須花費相當大的成本在故障排除的工作上,若能建構一即時診斷環境,提供使用者隨時掌握加工的各項重要資訊,並於異警發生時提供適當的輔助機制,達成網絡化診斷維修之目的,此一課題值得深入探討與研究。

      本文提出以Web-based對於機械單元進行遠程診斷與後勤維修的解決方案。在機械故障異警方面分為兩大類,第一類為自我偵測型異警,針對此故障特性運用貝氏集合理論(Bayesian Set Theorem)並藉由FMEA之輔助建構智能化推論引擎,分析知識庫之中異警與失效原因的交叉關係與機率集合分布,改善傳統鏈結式之推論缺點。第二類為人工感知型異警,依據使用者觀察之現象而判定之異警故障,針對此類別應用案例式推論方法(Case-based Reasoning)建立診斷模型,以累積故障維修的知識技能,並結合後勤維修機制進而達成故障排除任務。為了驗證原型系統架構之可行性,以加工中心作為驗證對象,針對其嵌入式控制系統進行聯繫溝通,並與集中式遠程監控系統(NX-5 Remote Control System, RCS)進行整合與應用。本文為網絡化維修診斷的具體實施,奠定了一定的基礎,解決以往機械發生故障時,無法立即作出處置的窘境,並提昇設備運作之穩定性,加速工業自動化與電子化相互結合之推動。

      The manufacturing technology of machines is mature gradually, and to promote the machine functions is becoming more complex gradually in the same time. For the manufacturer, to possess a high-effect remote & maintenance platform, and then to handle machine alarm states in real time are very important. Formerly if the machine unit gave the alarms, manufacturers had to spend a lot of time to eliminate where the machine is breakdown. If it enables to build a real-time diagnosis environment, users might be able to obtain the information of manufacturing in real time. This function can offer users the problem solutions of manufacturing and breakdown. The topic merits discussion and study.

      This paper presented a web-based remote diagnosis and maintenance solution for machine units. Machines divide the alarm into two groups. The first group is the Auto-sense alarm. The diagnosis structure applies the Bayesian Set Theorem that is assisted with Failure Model & Effects Analysis (FMEA) to build an intelligent reference engine. It analyses the relationship between alarms and failure cases and improves the defect of the chain type reference. The second group is the Human-Sense alarm. It applies Case-based Reasoning (CBR) method to build the diagnosis model and accumulate a mass of maintenance knowledge. The prototype system combines diagnosis function and maintenance function and procures the target of eliminate breakdown.

      For testing and verifying whether the prototype system structure being feasible or not, the machining center is used as an experience subject. The system utilizes an embedded control system of MC as a communication platform and combined the NX5 remote control system. Some basis for concrete realization of e-diagnosis and e-maintenance is established in this paper. To solve machine units which give the alarm, manufacturers can’t eliminate machine faults in real time and improve the efficiency of the integration of the industry manufacture automation and electronic commerce.

    中文摘要................................................................... III Abstract ................................................................... IV 誌謝 .........................................................................V 目錄 ........................................................................VI 表目錄 ................................................................... VIII 圖目錄 ......................................................................IX 縮寫表 ......................................................................XV 第一章 緒論.................................................................. 1 1.1 研究背景與動機........................................................... 1 1.2 研究目的................................................................. 6 1.3 論文架構.................................................................11 1.4 研究步驟................................................................ 12 第二章 基礎理論與文獻探討................................................... 13 2.1 故障維修與診斷定義...................................................... 13 2.2 貝氏集合定理於異警集合之分析............................................ 15 2.3 階層式案例式推論於診斷應用.............................................. 21 2.4 故障模式解析方法........................................................ 27 2.5 電子化製造(e-Manufacture)............................................... 34 2.6 診斷維修與客戶關係管理(CRM)之關聯分析................................... 36 第三章 診斷模型建構......................................................... 38 3.1 異警事件分類與定義...................................................... 38 3.2 自我感知型異警集合關聯與推論............................................ 40 3.3 維修案例診斷推論........................................................ 47 第四章 診斷與維修系統模式分析............................................... 55 4.1 機械維修流程分析........................................................ 55 4.2 機械維修流程分析(原型系統整合原有流程)................................ 60 4.3 異警集合診斷流程與回饋分析(無編號異警)................................ 66 4.4 異警集合診斷流程與回饋分析(MLC & PLC2 異警)............................72 4.5 案例式推論流程與回饋分析................................................ 77 4.6 FMEA 失效性分析與機械可靠度分析......................................... 82 第五章 集中式遠程監控系統(NX-5 RCS)....................................... 84 5.1 嵌入式控制系統架構...................................................... 84 5.2 遠程監控方法............................................................ 90 5.3 系統規劃................................................................ 97 5.4 系統實現............................................................... 101 第六章 維修診斷系統實體架構與遠程監控系統整合開發.......................... 106 6.1 系統建構相關工具與技術................................................. 106 6.2 診斷維修資料庫建構..................................................... 107 6.3 維修診斷系統功能架構....................................................111 6.4 遠程監控系統整合....................................................... 121 第七章 應用實例驗證........................................................ 126 7.1 系統實體展現........................................................... 126 第八章 結論與建議.......................................................... 145 8.1 結論與成果............................................................. 145 8.2 未來研究方向與建議..................................................... 146 參考文獻................................................................... 148 附錄A、FMEA 要因評分說明表................................................. 152 附錄B、異警檢查表.......................................................... 154 作者簡介................................................................... 161

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