Predictive Maintenance of Liquid Paint Supply Systems

Abstract

A method and associated paint finishing system are disclosed for performing predictive maintenance on equipment used for delivering liquid paint in a paint finishing facility. The method comprises: identifying a set of components of the equipment and associated maintenance requirements; for each of the components, providing a set of operating parameters (401-404) that affect useful service life of the component; for each component, providing an algorithm (410) relating the operating parameters to a remaining time by when a maintenance operation on the component is to be performed; monitoring each of the operating parameters (401-404) during operation of the paint finishing facility; for each component, applying the algorithm (410) with the monitored operating parameters (401-404) to calculate the remaining time for the component (420); and for each component providing to a maintenance operative an alert indication relating to the remaining time for the component.

Claims

1. A method of performing predictive maintenance on equipment used for delivering liquid paint in a paint finishing facility, the method comprising: identifying a set of components of the equipment and associated maintenance requirements; for each of the components, providing a set of operating parameters that affect useful service life of the component; for each component providing an algorithm relating the operating parameters to a remaining time by when a maintenance operation on the component is to be performed; monitoring each of the operating parameters during operation of the paint finishing facility; for each component, applying the algorithm with the monitored operating parameters to calculate the remaining time for the component; and for each component providing to a maintenance operative an alert indication relating to the remaining time for the component.

2. The method of claim 1, wherein the operating parameters comprise one or more of paint tank levels, paint movement between paint tanks, pressure at any point in a paint finishing system, paint flow, paint velocity, motor speed, temperature, pressure in a paint filter, oil level, noise, wear, and greasing schedules.

3. The method of claim 1, wherein the operating parameters further comprise an abrasive factor configurable to account for the abrasiveness of the liquid paint being pumped.

4. The method of claim 1, wherein the operating parameters comprise an average pressure and flow rate.

5. The method of claim 1 further comprising the step of recording data relating to the operating parameters during operation of the paint finishing facility.

6. The method of claim 5 further comprising the step of providing to a maintenance operative an indication as to how much work a component has completed.

7. The method of claim 6 wherein the indication is based on an average value of pressure and/or cycle rate said component has been subject to.

8. The method of claim 1 further comprising the step of storing a set of maintenance settings on a removable memory storage device.

9. The method of claim 1 further comprising the step of configuring a graphical user interface to display the alert indication for one or more components.

10. The method of claim 1 further comprising the step of interfacing with job queue data in order to predict future operating parameters of a component.

11. The method of claim 1 further comprising the step of uploading to a server a first set of data relating to the remaining time for each component and operating parameters of each component.

12. The method of claim 11 further comprising the step of; downloading from the server a second set of data derived from both the first set of data, and, data uploaded to the server using a plurality of other instances of the method corresponding to the method of claim 11.

13. The method claim 12 further comprising the step of configuring the controller of any of the plurality of paint finishing systems to adjust operating parameters of components based on the second set of data.

14. The method of claim 12 further comprising the step of processing the data that has been uploaded to the server in order to determine an optimal set of operating parameters for configuring components in order to increase the remaining time for components.

15. A paint finishing system comprising: equipment used for the delivery of liquid paint, including components having associated maintenance requirements; monitoring devices configured to monitor operating parameters that affect useful service life of the components; at least one controller having a memory and a processor, wherein the memory stores, for each component, an algorithm relating the operating parameters to a remaining time by when a maintenance operation on the component is to be performed, and wherein the processor is programmed, for each component, to apply the algorithm with the monitored operating parameters to calculate the remaining time for the component and to provide an alert indication relating to the remaining time for the component.

16. The system of claim 15 wherein at least one of the components is a pump.

17. The system of claim 16 wherein the pump comprise one or more of any of the following; a cam follower bearing, a bearing, a cam, a fluid seal, a gearbox or a bellow.

18. The system of claim 15 wherein the memory of the controller is integrated into a removable memory storage device.

19. The system of claim 15 wherein there is one controller per component.

20. The system of claim 15 wherein the controller is replaceable.

21. The system of claim 15 wherein the controller comprises at least one control card operable to provide a data link to a computing device.

22. The system of claim 15 further comprising an interface with job schedule data stored on a hard drive of the computing device.

23. The system of claim 15 wherein the controller further comprises a data connection to a server, wherein; the processor of the controller is programmed to upload a first set of data relating to the remaining time for each component and operating parameters of each component to the server using the data connection.

24. The system of claim 23 wherein the processor of the controller is programmed to download a second set of data derived from data uploaded to the server.

25. The system of claim 24 wherein the controller is configured to adjust the operating parameters based on the second set of data.

26. A server comprising: a processor and memory; a plurality of data connections to controllers of paint finishing systems; wherein the processor of the server is programmed to; use the plurality of data connections to receive a first set of data comprising operating parameters and an amount of remaining time by when a maintenance operation is to be performed on components within each paint finishing system and store the first set of data on the memory; and use the plurality of data connections to transmit a second set of data derived from the first set of data.

27. The server of claim 26 wherein for each component of a paint finishing system, the processor is programmed to process the first set of data in order to determine optimal operating parameters that when applied to each component increases the amount of remaining time before a maintenance operation is to be performed on components; and storing this information in the second set of data.

Description

BRIEF DESCRIPTION OF FIGURES

[0054] FIG. 1 is a schematic representation of a known paint circulation system.

[0055] FIG. 2 is a first example screenshot from a computing device running a piece of computer software in accordance with an embodiment of the present invention.

[0056] FIG. 3 is a second example screenshot from a computing device running a piece of computer software in accordance with an embodiment of the present invention.

[0057] FIG. 4 is a schematic block diagram showing data transfer that takes place in a method and system in accordance with an embodiment of the present invention.

[0058] FIG. 5 is a third example screenshot from a computing device running a piece of computer software in accordance with an embodiment of the present invention.

[0059] FIG. 6 is a schematic block diagram showing multiple paint finishing systems connect to a server in accordance with an embodiment of the present invention.

[0060] FIG. 7 is a flow diagram showing a method in accordance with an embodiment of the present invention.

[0061] FIG. 8 is a flow diagram showing a portion of a method in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

[0062] Referring to FIG. 1, there is shown an example paint circulation system that would be found in a paint finishing facility to which an embodiment of the claimed method may be applied. Paint circulation system 20 includes paint tank 11 containing a reservoir of liquid paint. Hereinafter, the terms Smart Pump or Smart Back Pressure Regulator (Smart BPR) refer to an automatically controlled variable Pump or BPR that is connected to a paint circulation system such as that disclosed in European Patent EP1789202B1. Such a so-called smart system may be configured to automatically control devices such as pumps or BPRs via a connection to a controller 26. As discussed above, the so-called smart system may be configured to intelligently adjust the settings of any devices/components in the system in order that the flow rate in the system is reduced when paint material is not in demand. A smart pump 22 is operable to supply paint from the paint tank 11, optionally through a paint filter 13, to a spray booth 14. The spray booth 14 typically includes one or more applicators 16. For example, these may be spray nozzles manipulated by robot arms. Paint not used in the spray booth 14 is circulated back to the paint tank 11 via an automatically controlled smart BPR 25. The smart pump 22 and smart BPR 25 are controlled from a controller 26. A signal from pressure sensor 24 is provided as an input to the controller 26. The controller 26 may be a programmable logic controller (PLC) or other suitable programmable device. The controller 26 may comprise memory storing control or maintenance settings. The controller 26 may be replaceable in order that different control or maintenance settings are applied or transferred to new pumps. The controller 26 may incorporate data connection interfaces allowing connection for data transfer with other computing devices.

[0063] As discussed above, the smart pump 22 intelligently maintains a reduced pressure in the paint line when paint material is not in demand such that a reduced level of wear on components is permitted, whilst retaining the required circulation to prevent settling of pigmentation.

[0064] An example of such a paint circulation system is described in the granted European patent application EP1789202B1, the contents of which are hereby incorporated by reference.

[0065] Whilst controller 26 is shown as receiving an input from pressure sensor 24, inputs may be received from multiple components. For example, inputs may be received from cam follower bearings, main bearings, cams, fluid seals, bellows, and greasing schedules (parts not individually shown). The inputs may comprise operating parameters such as paint tank levels, paint movement, pressure, flow rate, paint velocity, pump speed, pressures before and after the paint filter, temperature. Operating parameters may be monitored during operation of the paint finishing facility.

[0066] Referring to FIG. 2 there is shown an example screenshot from a computing device (not shown) running a piece of smart pump software. The computing device interfaces with controller 26 (only shown in FIG. 1) in order to display a live status of operating parameters 201. This information may, or may not be displayed on the computing device (not shown), in either case, the operating parameters 201 are monitored by the smart pump software. An algorithm (not shown) is applied to the monitored operating parameters in order to determine the remaining time for components (i.e the remaining amount of time before they require maintenance attention). Elements of the smart pump software may run on controller 26 or the computing device. The computing device may be, for example, a desktop PC, laptop, or a tablet.

[0067] The algorithm may be in the form of an equation or set of equations where an output (the remaining time for components) is determined by performing a calculation based on inputs being operating parameters. The algorithm may be implemented in the form of look-up tables or other accessible data storage/matching methods. For example a list of possible inputs and outputs may be stored in computing memory on a database. The correct output may be retrieved from this database using a matching process or similar.

[0068] The live operating parameter status may be recorded onto the memory of the controller 26 or a removable memory storage device (not shown). This data may be input to the algorithm to calculate the remaining time for components. The data may be transferred via the removable memory storage device to different pumps so that the data can continue to be utilised even when new pumps are added or a new factory is built containing pumps.

[0069] Referring to FIG. 3, there is shown an alert indication relating to the remaining time for components according to an embodiment of the present invention. The alert indication is in the form of an alert window 301 that may be displayed on the screen of a desktop computer, tablet, or laptop that is running the smart pump software program. The alert window 301 may comprise component labels 303 associated with time indicators 304 and maintenance instructions 305. The component labels 303 shown here comprise an example set of components that have been identified. The instruction 305 may be associated with multiple component labels 303 and time indicators 304 as shown, for example, under the BEARING GREASING instruction. The time indicators 304 indicate the time remaining for the component that may be calculated using an algorithm relating to operating parameters that affect useful service life of the component.

[0070] Some components may have an abrasive factor 305 configurable to account for the abrasiveness of the material being pumped. A maintenance operative viewing alert window 301 can view the current abrasive factor and may be able to manually change it depending on the type of paint being used. The time indicators 304 may be automatically updated using the algorithm when the abrasive factor is manually changed using a computing device running the smart pump software program.

[0071] A maintenance operative viewing alert window 301 is able to monitor components during operation and thereby determine which components require attention. By reading the maintenance instructions 305, the maintenance operative knows what action to perform in order to ensure the components are properly maintained. The time indicators may be colour coded depending on how critical component maintenance is required. The viewing alert window 301 may be completely customizable using the smart pump software program. For example, when setting up the system, only some time indicators may be displayed, or information relating to multiple pumps may be displayed.

[00001]$\begin{array}{cc}{\mathrm{Life}}_{10.Math..Math.\mathrm{Hours}}=\frac{1.Math.\text{,}.Math.000.Math.\text{,}.Math.000}{60.Math..Math..Math..Math.\mathrm{speed}}\left[\frac{/\mathrm{Bearing}.Math..Math.\mathrm{Rating}.Math.{\backslash }^{33}}{\mathrm{Bearing}.Math..Math.\mathrm{Load}}\right)& \mathrm{Equation}.Math..Math.1\end{array}$

[0072] Referring to Equation 1 there is shown an example equation that may be programmed into an algorithm of embodiments of the present invention. This equation is a standard calculation used by bearing manufacturers to predict bearing life (or the remaining time for a bearing). It shows that Bearing Speed (Speed) has a relatively small effect on bearing life, and, that Bearing Load is the main factor affecting bearing life. In embodiments, the algorithm may utilise this equation in conjunction with collective data obtained from sources such as prior use of components, predicted future use of components using job queue data (discussed in more detail below) and data from other systems obtained via a network (also discussed in more detail below). Utilising such data allows for predictions to be fine-tuned and to be more accurate.

[0073] In the shown embodiment, the alert indication takes the form of a window of the smart pump computer program having a graphical user interface. The operative is only alerted to the remaining time of components when viewing this window. It is also possible for the alert indication to take the form of an alarm, lights, text message, or any other form of electronic notification or visual cue.

[0074] Referring to FIG. 4, a flow diagram showing example inputs to the algorithm is shown. The algorithm 410 may process inputs on the controller 26 or on the computing device (not shown). The algorithm 410 may consider the load that under which components are placed in order to determine the remaining time of components. The load may depend on operating parameters such as pressure 402, flow rate 401, cycle rate 403, or other operating parameters 404. In a smart pump, pressure and flow rate may vary. For example, these values will be lower during periods where paint is not actively being sprayed. The calculated remaining time of components 420 takes these factors into account and provides an accurate remaining time rather than merely utilising the cycle rate as is typical in prior art methods. The value of remaining time 420 may be processed and/or presented on a computing device to a maintenance operative via the alert indication as discussed above. The pressure 402 and flow rate 403 may be recorded into memory 430 and the algorithm 410 may consider the time history of these values. The algorithm may consider average values of pressure, cycle or flow rate. Use of such inputs provides for improved accuracy in determining the remaining time, compared to traditional methods of merely using a single equation such as the equation shown in Equation 1.

[0075] For some components, the operating parameters further comprise component-specific parameters such as an abrasive factor 406 that accounts for the abrasiveness of the liquid being pumped in relation to the material of the component. For example, seals may wear out due to the abrasiveness of paint liquid. The rate of such wear may also depend on other operating parameters such as pressure and flow rate.

[0076] The algorithm 410 may receive input from job queue data 407. Job queue data may comprise data collected by software that monitors the position of parts throughout an automotive OEM, Tier 1 or industrial plant once the parts have been loaded on a conveyor system. The job queue data may be used to provide demand signals to the colour valves to turn on and turn off the supply of paint to the applicators 16 in the spray booth 14. The job queue data 407 provides an indication as to how much load particular pumps will be placed under during a future period of time. For example, the algorithm may determine that a high number of car parts are to be sprayed red and that; as a result, the red paint pump will require maintenance at a future point in time. Maintenance can therefore be undertaken during an appropriate maintenance interval. The algorithm may further prepare a maintenance schedule based on the planned workload of different pumps.

[0077] Referring to FIG. 5, there is shown a maintenance alert indication in accordance with some embodiments of the invention. The component labels 303 are displayed and colour coded depending on maintenance actions that are to be taken. Maintenance instructions 305 are displayed below the component labels 303.

[0078] Referring to FIG. 6 there is shown a diagram of how multiple paint finishing systems connect to a server according to some embodiments of the present invention. The controllers of paint finishing systems 1, 2 and 3 (603, 604, 605) connect to the internet 601 via internet connections 606a-d. The controllers may comprise a control card directly interfaced with components. Alternatively the controller is a desktop computer or any other type of computing device having network connectivity. The controller may comprise both a control card and a desktop computer. The server 602 is connected to the internet via connection 607. Connections 606a-d and 607 could comprise wireless (such as WiFi) or wired connections through a modem interfacing with an internet provider. Whilst in the embodiment shown there are only three paint finishing systems 603, 604, 605, it will be appreciated that there could be many more systems, for example hundreds or thousands. Likewise, there could be many more servers. The server 602 may be a commercial cloud computing service such as Microsoft cloud platform.

[0079] The paint finishing systems 603, 604, 605 are connected to the server via the internet 601. The controllers (not shown) of the paint finishing systems may record operating parameters and time remaining values for components and store this first set of data on memory. The first set of data may be periodically synchronised (uploaded) to the server at set time intervals. In this case, it is not necessary for the paint finishing systems to be permanently connected to the server via the internet. Alternatively, the operating parameters and time remaining values may be uploaded to the server in real time.

[0080] The server 602 processes the first set of data and generates a second set of data. The second set of data may be a statistical analysis of the first set of data. For example, it may contain values such as the average number of times a pump needs to be replaced for each pump cycle rate that a pump may be operated at. The second set of data is transmitted via the internet 601 to paint finishing systems 606a-c. An operative may view the data using computer software installed on the controller. He may also use software to manipulate the data to obtain useful information such as what the optimal pump cycle rate setting is to ensure maintenance requirements are economical based on data obtained from other paint finishing systems.

[0081] Referring to FIG. 7, there is shown a flow diagram representing a method in accordance with embodiments of the present invention.

[0082] Initially, as per step 701, a set of components and associated maintenance requirements are identified. Maintenance requirements may be determined with reference to manufacturer literature.

[0083] In step 702, for each component, a set of operating parameters is provided that affect the useful service life of the component. For example, if the component is a pump, then operating parameters may include cycle rate and pressure.

[0084] In step 703, an algorithm is provided for each component relating operating parameters to a remaining time by when a maintenance operation on the component is to be performed. For example, the algorithm may determine that if the pump is operated at a particular cycle rate and pressure for a given length of time, then a maintenance operation of replacing the pump must be undertaken in two weeks. Accordingly, each of the operating parameters are monitored during operation in step 704. At the same time, data may be recorded relating to the operating parameters during operation in step 705. The data may be used to further improve the efficiency of components as discussed above. Maintenance settings may be stored on a removable memory storage device as per step 706 in order that they can be easily copied to other components. Maintenance settings may comprise data relating to the time remaining by when a maintenance operation on a component is to be performed based on past usage of the component. Whilst steps 705 and 706 are shown in FIG. 7 to take place in conjunction with step 4, these steps could also take place in conjunction with any other step such as step 707.

[0085] During step 707, the algorithm is applied with the monitored operating parameters to calculate the remaining time for the component. As discussed above, the algorithm may be an equation having an input and an output. Alternatively it may be a look-up table comprising a static set of data. The method may involve interfacing with job queue data in order to predict future operating parameters of a component as per step 708. Step 708 may take place at any point in the shown method.

[0086] During step 709, a maintenance operative is provided an alert indication relating to the remaining time for the component.

[0087] Referring to FIG. 8, there is shown a flow diagram representing a portion of a method in accordance with embodiments of the present invention. The first step of this method 801 may place after any of the steps as shown in FIG. 7 from when the remaining time has been calculated such as step 703.

[0088] In step 801, a first set of data is uploaded to a server. The first set of data relates to the remaining time for each component and operating parameters of each component. The data may be uploaded from multiple paint finishing systems and may be via the internet.

[0089] In step 802, the data is processed to determine an optimal set of operating parameters for configuring components in order to increase the remaining time for components. This processing may be undertaken on the server (i.e using the processor and memory of the server).

[0090] In step 803, a second set of data derived from the first set of data is downloaded. Typically, this process will take place using a computing device or controller in a paint finishing system.