Remote diagnosis system for concrete machinery faults

Concrete machinery is bound to encounter various faults during on-site construction. Once the on-site personnel cannot be eliminated, if the manufacturer is asked to send someone for maintenance, it will take a very long time. Moreover, as the manufacturer is far from the equipment site, it cannot make an accurate judgment. Therefore, when going out, it cannot accurately prepare the required spare parts, which will cause another wait.

Therefore, it is necessary to establish a remote fault diagnosis system, that is, to display the situation of the equipment working site on the Internet in the Internet Explorer browser of the computer in the diagnosis center. The diagnosis center conducts detailed analysis and judgment based on the actual working situation of the displayed equipment, providing real-time services for manufacturers and service stations in distant places, which greatly facilitates the use of users and saves maintenance time. The diagnostic center can also be managed in real time via the Internet, including reading data, issuing instructions, and so on.

1? The establishment of a remote fault diagnosis system

A complete remote fault diagnosis system should include personnel, equipment and networks, which respectively complete the processes of fault feedback, analysis and judgment, instruction issuance and real-time service to ensure the effective operation of the entire system.

(1) Staffing

Personnel are at the core of the entire system. The level of professional theoretical literacy and the amount of practical experience of service engineers directly affect the efficiency of the system. It is not about the number of people but their quality and specialization. They can be equipped at a standard of 3 to 5 people per thousand units. It is generally believed that the service engineer of the diagnostic center should have over 10 years of working experience in the production and maintenance of concrete machinery, as well as the experience of repairing over a thousand faulty items. They should be able to accurately identify the faulty parts of the mechanical, electrical and hydraulic systems of concrete machinery through listening to sounds, reading pictures and the introduction of on-site personnel, point out the maintenance methods, and dispatch the spare parts center warehouse to deliver spare parts. Estimate the frequency of faults and the replacement time of vulnerable parts based on the operation and usage of the equipment, and dispatch spare parts in advance. In the profound and extensive Chinese medicine, there are "observation, auscultation and olfaction, inquiry, and palpation", which actually demand doctors' superb medical skills. They should be able to see the big picture from the small details and judge the health status of the five internal organs through surface phenomena. A good service engineer should also possess these abilities to see through the surface to the essence. One should also possess standard and clear language expression skills, profound insight and a spirit of taking responsibility.

(2) Network construction

The network is the skeleton of the entire system. The rapidly developing Internet provides a solid guarantee for remote diagnosis systems. The network construction of remote diagnosis systems includes applying for large-capacity email boxes, dedicated web pages or websites. The remote diagnosis center and terminal personnel form rapid information transmission and feedback through the network to complete the diagnosis and handling of faults.

(3) Hardware facilities

Hardware facilities include product component catalogues, digital devices, etc., which are used to solve the problem of unclear explanations over the phone. Some operators cannot accurately describe faults due to factors such as accents, dialects or professional terms. The causes of some faults are very complex, all of which require comprehensive judgment based on photos, images, sounds, etc. Nowadays, many digital cameras have video recording functions, which can transmit dynamic information of the equipment and provide more detailed data for diagnostic centers. Mobile phones that can take photos or record audio can convey information more quickly. The 3D product component diagrams can be directly sent to the end users, facilitating the operators to check and eliminate faults according to instructions and accurately identify the components that need to be replaced.

(4) Spare parts central warehouse

The spare parts central warehouse should be built in the central city of the region, equipped with emergency delivery trucks, and closely related to several express delivery centers. It should have a sufficient reserve of spare parts for all products and undertake the functions of distributing spare parts and recycling used parts. Branch warehouses can also be set up on construction sites where equipment is relatively concentrated.

2? The Application of remote Fault Diagnosis System

Once, a concrete machine at a remote construction site suddenly broke down. The operator repeatedly tried to troubleshoot, but the equipment still did not respond. Later, they called the service hotline attached at the back of the manual. After some negotiation, both sides roughly agreed that there was a problem with several parts in the middle. So, the service personnel took these parts and rushed to the construction site as quickly as possible. Disassembly and inspection revealed that it was caused by a loose screw. The fault was quickly eliminated. To prevent potential problems, the user requested to keep these spare parts, and the manufacturer agreed. Both sides were happy.

The usage requirements for concrete machinery are relatively high: once the concrete stops being stirred, it will set initially very quickly, and it needs to be scrapped if it exceeds 2 hours. If the concrete is still inside the equipment, efforts must be made to discharge it as soon as possible; otherwise, the equipment will also suffer significant losses. Therefore, upon discovering a fault, the operator should immediately report the information to the diagnostic center. The center will determine whether to repair or replace based on these materials. If it is considered repairable, instruct the on-site operator to remove a certain part according to the three-dimensional component diagram of the equipment for maintenance. If it is deemed necessary to replace, instruct the nearest spare parts warehouse to promptly deliver the spare parts. Speed and accuracy are the basic requirements for the remote fault diagnosis system of concrete machinery. Full-information real-time dialogue is the feature that distinguishes the remote fault diagnosis system from the general service hotline.

The remote fault diagnosis system in operation requires someone to be on duty 24 hours a day to ensure the normal operation of the entire feedback system, which is particularly important in the continuous pouring of concrete. However, due to the popularization of community broadband and laptops, the duty personnel can also work from home, making the entire system "scattered in form but concentrated in spirit".

The use of a remote fault diagnosis center system can significantly enhance the accuracy and timeliness of maintenance, save manpower, reduce service costs, and at the same time increase the selling points of products, improve the corporate image, and effectively promote market sales.