OPERATION DATA-RECORDING SYSTEM FOR A MACHINE

Abstract: This invention provides a system for recording operation data of a machine, wherein a program for converting sygnals stored through a sensor or measuring means into operation data in conformity with the increase or alteration of the sensor or measuring means due to the operation status of the machine or to the type of the component of the machine is preliminarily stored in one or seperate card-type external memory or other transportable external memory. The terminal of the system is designed to allow an connection of various kinds of the sensor or measuring means. Accordingly, it is possible to conduct processing and recording of various kinds of operation data by exchanging the external memory stored with a prescribed operation data-processing program, or by changing the writing of the program. It is also possible to record operation data in the external memory stored with the operation data-processing program after the program is read out to simplify the operation of an operator.

Description: This invention relates to a recording system for recording in an external transportable memory device operation data of a machine, for example, an earthworking vehicle such as an off-highway truck or a loader, a heavy duty vehicle, and a plant, and more particularly to a system having a general-purpose property in its operation data-recording device. In order to control the operation of vehicles, a tachograph has been utilized to record analogue representations of speed, traveled distance and engine speed on a uniformly rotating cylindrical recording paper with a printing needle. Since the recording by such a tachograph is limited to a mechanical measurement and the recording paper therefor is narrow in width, it is very difficult to accurately read the recorded data and it is impossible to automatize the processing of the recorded data (such as automated calculation of an average speed or total traveled distance). In JP-A-58/084394 a digitalized operation control system is disclosed which comprises a recording device mounted on a vehicle such as a truck, a bus and a taxicab, and an analysis device set up on the ground, and wherein the recording device stores not only data entered by a driver for preparing a daily report, but also other data such as traveled distance and speed which can be automatically stored at predetermined time intervals. When the memory device housed within the recording device and stored with above various data is connected to the analysis device set up on the ground, an operational daily report is automatically supplied. An employment of a recorder/analysis device comprising a microcomputer as mentioned above makes it possible to automatize the processing of operation data. Since operation data required for a specific operation control of an earthworking vehicle, a vehicle for any work or other machine differs in accordance with the content of the operation, in addition to each of an operation data-detecting and measuring device which is specific to the content of the operation, the specification of the data-recording device is also required to be separately prepared. Under the circumstances, it is highly desired to develop an operation data recording system of extendable and general-purpose property wherein it is possible to increase the capacity thereof in accordance with the operation conditions of a machine, or to interchange a processing program for conducting the conversion of measured signals stored from each different sensor or measuring means into operation data. It would be also desirable if it were possible to store the processing program of the operation data in an SC card or other external memory, and to record an operation data within the external memory after performing the reading of the program with an operation data-recording device. DE-A-32 32 416 discloses an operation data-recording system according to the preamble of claim 1. The known system comprises a detecting device which is installed in a vehicle and can comprise a check program memory storing several checking routines. Alternatively, the check program memory can be contained in a transportable external memory which can be connected with the detecting device. An object of this invention is to provide an operation data-recording system of extendable and general-purpose property, which can be utilized in combination with an external memory. This object is achieved by the features mentioned in Claim 1. Brief Description of the Drawings Fig. 1 is a function block diagram; Fig. 2 is a function block diagram showing one embodiment of this invention as applied to an off-highway truck; Fig. 3 is a flow chart showing a control procedure of an operation control means contained in the system of the embodiment shown in Fig. 2; and Fig. 4 is a flow chart showing a processing procedure of the operation processing means of the embodiment shown in Fig. 2. Fig. 5 is a block diagram showing another embodiment of this invention, wherein operation data are dually stored in an external memory. Fig. 1 shows a block diagram indicating the function of an operation data-recording system of a machine according to this invention. This operation data-recording system comprises a transportable external memory 4 as a memory medium, a reader 3 for reading an operation data-converting program stored in the external memory 4, an operation data conversion means 1 for converting signals supplied from a sensor or measuring means S through a signal input terminal 2 on the basis of a program which is preliminarily supplied, and a writing means 5 for writing operation data obtained by the operation data conversion means 1 in an external memory 6. The signal input terminal 2 is so designed that various kinds of sensor or measuring means S can be connected therewith through an interface, thereby allowing the connection of any desired sensor or measuring means therewith in conformity with the operation content of a machine. Reader 3 reads an operation data conversion (processing) program stored in the transportable external memory 4 to store it in the operation data conversion means 1. The signals stored by this program are processed into operation data. In this external memory 4 or operation data conversion means 1 is stored a control program for calculating operation data on the basis of signals supplied from the terminal 2 by the execution of an operation data-processing program, and outputting the operation data thus obtained to the writing means 5 or an external display means 8. Accordingly, detected or measured signals stored through the terminal 2 are converted into operation data by an operation data-processor 1B which is controlled by a controller 1A of the operation data conversion means 1, and are then supplied as an output. In the writing means 5, the operation data thus supplied are recorded in the external memory 6 which is detachably fit to the writing means 5. If desired, the external display means 8 may be provided for displaying the operation data. In this case, an external display output terminal 7 may be disposed as indicated in a dotted line. This output terminal 7 is so designed that one or more external display means 8 such as CRT, LED or printer may be connected therewith. "K" shown in Fig. 1 indicates an external input means for allowing an operator to store predetermined data therein. Next, the operation data-recording system for a machine will be explained with reference to Figs. 2 to 4, which show one embodiment as applied to an off-highway truck. This operation data-recording system comprises a plurality of sensors Sn, an external memory comprising an IC card 4, and a microcomputer 10 comprising a measurement signal input terminal 2, an IC card reader 3 and an IC card writer 5. The measurement signal input terminal 2 in this embodiment has six terminals T1-T6. The terminal T1 is a terminal for a speed sensor S1, which detects the speed of a vehicle from the rotation speed of wheels or a speed meter. The terminal T2 is a terminal for an engine speed sensor S2, which detects the engine speed. The terminal T3 is a terminal for a dump-switch 53 connector, which detects the number of up and down movements of a vessel. The terminals T4 and T5 are terminals for extension. The terminal T6 is a terminal for connecting with a starter switch (a disconnector switch) S6 of a vehicle. These sensors S1-S6 supply measurement signals (or detection signals) to the microcomputer 10 through an interface I/F. This microcomputor 10 is connected to the battery of a vehicle through a connector cable to receive electricity. In this embodiment, these sensors S1-S6 are all mounted on a vehicle. However, these measured signals may be supplied through a measurement device set up out of the vehicle to the microcomputer 10. Reference mark CH indicates a transmitting terminal for RS232C, which is utilized for storing data on the loaded weight, which are measured with a load weight-measuring device (or dumpscale) S7 set up on the operation site, in the microcomputer 10 via a serial transmission. The input terminal 2 communicating with an input port 1a of the microcomputer 10 is so designed as to allow connections through the interface I/F with various kinds of sensors or measuring devices for detecting operation control data in addition to the sensor mentioned above, and therefore has extendable and general-purpose properties. The IC card reader 3 performs readings of the operation data-processing program and the operation data-control program stored in the IC card 4, and supplies the information thus obtained to the microcomputer 10. The operation data control program is preliminarily stored in the memory of the microcomputer 10. A list of programs each corresponding to the object of control of operation data as well as to the type of the sensor or measuring means mounted on a vehicle is written into this IC card 4 by a controlling operator using a program-setting device 20 comprising a microcomputer. The operation data-processing program stored in this IC card 4 is transmitted to the microcomputer 10 through the IC card reader 3 and the input port 1a, and then processed by this microcomputer 10. Accordingly, if a different operation data-processing program is applied to the system, the same measurement signals can be processed in various ways of data processing, for example in a time-sequential way or as a histogram. When a different measurement signal is stored, corresponding operation data can be processed. Accordingly, the microcomputer 10 is clear with respect to the operation data processing. The microcomputer 10 into which a program stored in the IC card 4 is to be read according to this embodiment comprises; a vehicle speed data processing means 11 to obtain vehicle speed data at a unit time interval on the basis of signals supplied from the vehicle speed sensor S1; a traveling distance data-processing means 12 which makes use of the vehicle speed data and traveling time data obtained from a timepiece T of the microcomputer 10; an engine speed-processing means 13 to determine the engine speed at a unit time interval on the basis of signals supplied from the engine speed sensor S2; a dump interval data-processing means 14 for obtaining dump interval data from the timepiece T on the basis of signals from the dump-switch S3, and for calculating a traveled distance corresponding to the dump interval data; and a load weight data-processing means 15 which determines load weight data supplied from the load weight-measuring device as a load weight value at the time of the dumping operation. If desired, an operation data-judgement means 16 may be further provided in the microcomputer 10 so as to make a comparison between the operation data obtained by the operation data-processing means and predetermined standard values, and to indicate the result in an external display device and the like. The IC card 4 or the memory of the microcomputer 10 also stores therein an operation data-control program with which the operation data-processing program mentioned above is executed, and various kinds of operation data supplied from the sensors are stored in the operation data-processing program for supplying these data afterwards the IC card writing device 5 or to the external display device 8, thereby forming an operation data-control means 18. With this operation data-control means 18, a list of programs is read out of the IC card 4 by means of the IC card-reading device 3 in the first step (1) as shown in the flow-chart of Fig. 3. In the second step (2), ID code judgement is conducted on the operation data-recording IC card 6, which is introduced in the IC card-writing device 5. When the ID code is judged to be suitable, the IC card-writing device 5 is driven in the third step (3) and the IC card 6 is made ready to accept writing therein. In the fourth step (4), each of the operation data-processing programs is executed and measured values from the sensor or measurement device are stored to obtain each operation data (the fifth step (5)). The operation data thus obtained are temporarily stored in the RAM of the microcomputer in the sixth step (6), and then supplied to the IC card-writing device 5 in the seventh step (7) to conduct the writing into the IC card 6. The operation data may be directly transmitted from the fifth step (5) to the seventh step (7) to perform the writing. When the operation of the off-highway truck is completed in the eighth step (8) or when the operation data-processing program is terminated or required to be changed in the ninth step (9), the power supply to the microcomputer 10 is stopped and the IC card 6 is withdrawn from the IC card reader 3 in the tenth step (10), thereby finishing the operation of the operation data-processing program. The operation of each of the operation data-processing steps 11 to 15, which is based on the program stored in the IC card 4' is carried out in the procedure shown in the flow-chart of Fig. 4. First, it is determined if the IC card inserted into the IC card-writing device 5 is in agreement with a predetermined ID code. When it is determined to agree with the ID code, the IC card writing device 5 is set to ready to start the writing and the subsequent steps to follow. In the first step (1), the increase of the engine oil pressure is detected by a sensor, indicating the start of the engine. At this moment, if desired the time of start of rotation of the engine is recorded in the second step (2). Then, measurement signals stored from each of the sensors or measuring means as explained thereafter are converted into operation data. When the signals are of analogue values, they are required to undergo A/D conversion. The operation data thus obtained are treated either as time sequence data, or as a statistical data such as histogram data in the fourth step (4), or treated to be condensed. These data are written through the IC card writing device 5 in the SC card 6 after or without being stored in the RAM of the microcomputer 10 as a virtual memory (the sixth step (5)). When the revolution of the engine is determined as "0" in the seventh step (7), the time of that moment is stored in the eighth step (8) with the timer, and then, in the ninth step (9), a judgement is conducted whether the engine stop is temporary or not. When it is determined that the operation should keep going, the operator switches on to continue the operation, thereby returning the operation to the step (1). When it is judged that the operation should be terminated, the operator switches on a termination button thereby terminating the procedure. The operation data-processing procedure to be conducted in the step (4) on each of the measurement signals will be explained as follows. (1)Revolution number of the engine In this embodiment, the data of the revolution number of the engine per predetermined time period is stored as a pulse number and therefore is converted into the revolution number (when one revolution number is equal to four pulses, the revolution number can be calculated as : Pulse Number / 4), and stored in the data memory 6 in the form of time-sequence data in every unit time, or in the form of histogram as equally divided revolution number zones. (2) Traveling Speed and Distance The speed data are calculated on the basis of measurement signals from a speed meter, or by multiplying the revolution number per predetermined time period by the length of the circumference of the wheel. In this case also, these data can be stored in the form of time-sequence data or histogram in the IC card 6. The traveling distance is calculated by integrating a traveled distance with respect to time. (3) Weight of Load and Number of Dumping When the switch-on of the dumping is recognized, the time of the switch-on, the traveled distance from the moment of increased engine revolution up to present time, the weight of load immediately before the dumping operation, which is transmitted through RS232C interface from a load weight-measuring device such as a bucket scale are recorded and stored in the IC card 6. In this case, it is preferred that the writing of the load weight is conducted upon the input of a command to write. If the load weight-measuring device is so designed that the data of the load weight are extracted from the change in hydraulic pressure or strain of a supporting mechanism, in other words, if a sensor therefor is mounted on a vehicle, the sensor may be connected to an extended terminal T5 or T6 to store the measured signals, which will then be converted into the load weight by the microcomputer 10. Any data which are free from variable factor, such as date, a predetermined operation course, an operation site or identification number of a vehicle, are stored through an external input device "K" such as,for example, a keyboard in the microcomputer 10 in addition to the operation data. The operation data processed in this way are stored in the IC card 6 through the IC card-writing device 5, which is then withdrawn by an operator after the termination of the operation. This IC card 6 is subsequently inserted into an IC card-reproducing device (reader) 30A which is supervised by controlling personnel, and the operation data are read out. The operation data thus read out are then transmitted to a data analyzer (such as a hostcomputer) 30B comprising a microcomputer which is integral with or separate from the reader 30A, and subjected to data analysis in accordance with an operation control program and the like to prepare an operation daily report, an administration source material or an analysis source material. If the external display output terminals 7 (T10, T11) are optionally provided to the output port 1b of the microcomputer 10, data stored in the IC card 6 can also be supplied to a printer or plotter for preparing an administration source material together with a display device such as CRT, LED or LCD. Accordingly, the operation data can be taken out as a hard copy before they are displayed in the external display device (not shown) of the data analysis device 30B. When common operation data is required as in the case of an earthworking vehicle, a fundamental operation data-processing means (such as operation data-processing means for traveling speed or revolution number of engine corresponding to a tachograph in this embodiment) as well as an optional operation data-processing means (such as dumping interval data-processing means) should preferably be provided to the system body 10, so as to allow the selection of a desired optional operation data-processing means in conformity with the content of the operation. A single IC card may be commonly employed for storing the operation data-processing program as well as the operation data. In this case, if the IC card reader 3 and the IC card writing device 5 are integrally combined (IC card reader/writer), the operation of insertion and withdrawal of the IC cards 4 and 6 can be conveniently omitted. When this IC card comprises CPU and EPROM (or EEPROM), and has a relatively small capacity, all of the data (the above program) is erased, after the data have been read out with the IC card reader 3, by an erasing means (such as ultraviolet ray or electricity, which is not shown) so as to be utilized as a blank IC card for storing other operation data. In this invention, the external memory 4 for storing the operation data-processing program, as well as the external memory 6 for storing the operation data as processed are not limited to be an IC card as explained in the above embodiment, but they may be in any form of a transportable memory medium such as a card-type memory e.g. laser card, a magnetic tape, a memorypac, floppy-disk and photo-disk. The external memory may be provided with an intelligent function which performs a processing on the basis of stored data. Further, the operation data-processing means (the operation data-determining means) may also be provided with a malfunction-determining means which makes a judgement of whether predetermined standard values are exceeded or not by the detected data from sensors for detecting the operation e conditions of each of the components of a machine, such as a lubricating oil temperature sensor, a lubricating oil pressure sensor, an exhaust gas temperature sensor, an inhalated air temperature sensor, an inhalated air pressure sensor, a cooling water temperature sensor, a working member ejection pressure sensor or working oil temperature oil sensor. In this case, it may be preferable to provide to the operation data-processing means either a malfunction-alarm device for informing an operator or displaying to him in an external display device a malfunction of a specific component, or an emergency stop device for stopping the operation of the specific component or the heavy vehicle itself. It is also possible to provide the operation data-processing means (the operation data-determining means) with the optimum operation-determining means, which makes a judgement of whether each of the components of the vehicle is in an optimum operating condition (an optimum efficiency). In this case, it would be preferable to provide an instruction display means as an external display device for instructing an operator to adjust the operation, which performs a comparison between a predetermined optimum value and detected data obtained from a sensor for detecting operation efficiency such as an engine revolution sensor, a fuel supply sensor, a pumping volume-detecting sensor or a pump ejection pressure-detecting sensor. Fig. 5 shows another embodiment of this invention, wherein actual work data obtained from the work data-processing means 10A is written (recorded) as time sequence data and as statistic data, respectively, in output data IC cards 6A, 6B. When the detected signals are dually processed in the work data-processing means 10A to give both time sequence data and statistic data, these data are individually stored in separate external memories (IC cards). To be more specific, the data processed by the data-processing means 10A is transferred as it is through an output port 1b to the data writer 5 as a time sequence operation data and stored in the time sequence IC card 6A. At the same time, the time sequence data is output to the work data-statistic processing means. This statistic processing means is provided with a memory which preliminarily contains a program for processing work data in accordance with a control specification, and therefore is capable of carrying out a statistical processing of work data. In this embodiment, values of engine revolution and running speed are separated into suitable zones (numerical zones), and a judgement as to in which zone actual work data belongs is conducted and a histogram showing a total number of these values is utilized. The statistic data thus processed by the statistic processing means 10B is transferred one by one at each end of the operation, or totally after the completion of the whole operations, and written in the statistic data IC card 6B. This data writer 5 includes a card insertion portion into which the time sequence data SC card 6A as well as the statistic data IC card 6B can be detachably inserted with one-touch. Time sequence operation data can be written into the time sequence IC card 6A, and statistic data can be written into the statistic data IC card 6B by this data writer 5. The work data (or operation data) of each of the components may be written into an separate IC card 6A, or may be integrally written into one IC card 6A. A plurality of contact points and a plurality of semiconductor memories corresponding to the contact points may be provided in one IC card, thereby allowing simultaneous writing of both time sequence data and statistic data by using a plurality of writing heads. The time sequence data as well as statistic data may be individually stored in a virtual memory, thereby allowing these data to be alternately written into one memory such as an IC card. If these structures are adopted, a multi-recording of data in one memory can be realized. According to the system of this invention, measurement signals from sensors or measurement means adopted in accordance with the operation content of a machine are processed on the basis of a predetermined operation data-processing program prepared by operation administration I personnel, so that the operation data of various kinds of machine can be recorded by a single operation data-recording system and by optionally changing the operation data-processing program. Therefore, the system of this invention is superior in general-purpose property. Further, the system of this invention allows a very strict control of the operation of a machine by selecting a suitable operation data-processing program for collecting operation data under various operation conditions.

Claims: An operation data-recording system for a machine, including a sensor or measuring means (S; S₁ to S₆) for detecting or measuring an operation status of a machine; a terminal (2;T1 to T6) for storing measured signals from said sensor or measuring means (S; S₁ to S₆); a transportable external memory (4) containing a program for processing the measured signals from said sensor or measuring means (S; S₁ to S₆) to convert them into operation data; a reader (3) for reading said program, which is adapted to be detachably connected with said external memory (4); an operation data-processing means (1; 1O) for processing operation data according to signals from said sensor or measuring means (S; S₁ to S₆), which are supplied through said terminal (2), and following the program read by said reader (3); and a writing means (5) to record the operation data thus obtained through said operation data-processing means (1; 10) in an external memory (6); characterized in that the system is arranged to erase the program stored in the external memory (4) by an erasing means after storing the program in the operation data-processing means (1; 10) through the reader (3). The operation data-recording system according to claim 1, characterized in that the external memory (4) for storing the program is identical with the external memory (6) for storing the operation data. The operation data-recording system according to claim 1 or 2, characterized in that the operation data-processing means is provided with a malfunction-determining means to determine a malfunction of each of the components of the machine on the basis of the calculation of the stored operation data. The operation data-recording system according to claim 1, 2 or 3, characterized in that the operation data-processing means (1; 10) is provided with an optimum operation-determining means to determine an operation efficiency of each of the components of the machine on the basis of the calculation of the stored operation data. The operation data-recording system according to any one of the preceding claims, characterized by an external display output terminal (7, 8) for externally displaying the operation data obtained through the operation data-processing means (1; 10) with or without modification thereto. The operation data-recording system according to any one of claims 1 to 5, characterized in that the writing means (5) comprises a means which is capable of separately storing time sequence data and statistically processed data in the external memory (6) for storing the operation data.

Inventors: ATONO, TADASHI CATERPILLAR MITSUBISHI LIMITED, FUJIWARA, MASAO SAGAMIHARA MACHINERY WORKS, HISATAKE, TSUNEO CATERPILLAR MITSUBISHI LIMITED, MORITA, IZURU CATERPILLAR MITSUBISHI LIMITED, NAKAMURA, YOSHINOBU SAGAMIHARA MACHINERY WORKS, TOZAWA, SHOJI CATERPILLAR MITSUBISHI LIMITED
Applicants: MITSUBISHI JUKOGYO KABUSHIKI KAISHA, SHIN CATERPILLAR MITSUBISHI LTD.
Application year: 1985
Main classification: G07C5
IPC codes: G07C5, G01D9