Patent Publication Number: US-2020293014-A1

Title: Casting equipment monitoring system and casting equipment monitoring method

Description:
TECHNICAL FIELD 
     The present invention pertains to a casting equipment monitoring system and a casting equipment monitoring method. 
     BACKGROUND 
     Casting equipment can be operated continuously for 24 hours in order to increase production efficiency. On the other hand, given that casting equipment is operated continuously for 24 hours, it is necessary for the casting equipment to operate continuously without failure and for the quality of castings produced by the casting equipment to be maintained. For this reason, a 24-hour monitoring system for casting equipment is desired. 
     For example, Patent Document 1 discloses a system for remote support in which, when a molding machine in a foundry has trouble, the location of the trouble is identified from video image information taken of the molding machine, voice information obtained by recording a voice regarding the molding machine, and ladder program information from a control device of the molding machine. 
     CITATION LIST 
     Patent Literature 
     
         
         Patent Document 1: JP 4871412 B 
       
    
     SUMMARY OF INVENTION 
     Technical Problem 
     However, a monitoring system that detects that the condition of casting equipment is deteriorating before the casting equipment fails, or detects that the quality of castings produced by the casting equipment is deteriorating before it becomes clear that the castings are defective products, has not existed heretofore. 
     The present invention was made in view of the above, and a purpose of the invention is providing a casting equipment monitoring system and a casting equipment monitoring method for monitoring the condition of continuously operating casting equipment and the quality of castings produced by casting equipment. 
     Solution To Problem 
     In order to solve the problem described above and achieve the purpose, the casting equipment monitoring system in the present invention comprises: an information collecting device that collects, in real time, data measured by equipment within casting equipment; and a diagnostic device that compares, in real time, the collected data with a control value, and displays a diagnosis result if the diagnostic device determines that the collected data has deviated from the control value. 
     In addition, the casting equipment monitoring system in the present invention comprises: an information collecting device that collects, in real time, data measured by equipment within casting equipment; a diagnostic device that compares, in real time, the collected data with a control value, and transmits a diagnosis result if the diagnostic device determines that the collected data has deviated from the control value; and a diagnosis result reception device that receives and displays the diagnosis result. 
     In addition, the casting equipment monitoring method in the present invention comprises: collecting, in real time, data measured by equipment within casting equipment; and comparing, in real time, the collected data with a control value, and displaying a diagnosis result upon determining that the collected data has deviated from the control value. 
     In addition, the casting equipment monitoring method in the present invention comprises: collecting, in real time, data measured by equipment within casting equipment; a diagnostic device comparing, in real time, the collected data with a control value, and transmitting a diagnosis result to a diagnosis result reception device if the diagnostic device determines that the collected data has deviated from the control value; and the diagnosis result reception device receiving and displaying the diagnosis result. 
     Advantageous Effects of Invention 
     According to the present invention, an effect is provided in which it is possible to detect that the condition of casting equipment is deteriorating before the casting equipment fails, or to detect that the quality of castings produced by the casting equipment is deteriorating before it becomes clear that the castings are defective products. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a block diagram representing a functional configuration of a casting equipment monitoring system according to a first embodiment. 
         FIG. 2  is a block diagram representing a functional configuration of a diagnostic device. 
         FIG. 3  illustrates an overview of the casting equipment monitoring system. 
         FIG. 4  is a flow chart illustrating a method for monitoring casting equipment using the casting equipment monitoring system according to the first embodiment. 
         FIG. 5  illustrates an example of measurement data received by a diagnostic device. 
         FIG. 6  illustrates an example of a report generated by a control portion of a diagnostic device. 
         FIG. 7  illustrates other examples of reports generated by a control portion of a diagnostic device. 
         FIG. 8  illustrates other examples of reports generated by a control portion of a diagnostic device. 
         FIG. 9  illustrates other examples of reports generated by a control portion of a diagnostic device. 
         FIG. 10  illustrates other examples of reports generated by a control portion of a diagnostic device. 
         FIG. 11  is a block diagram representing a functional configuration of a casting equipment monitoring system according to a second embodiment. 
         FIG. 12  is a block diagram representing a functional configuration of a diagnostic device. 
         FIG. 13  is a block diagram representing a functional configuration of a diagnosis result reception device. 
         FIG. 14  illustrates a catalog explaining a casting equipment monitoring system. 
         FIG. 15  is a flow chart illustrating a method for monitoring casting equipment using the casting equipment monitoring system according to the second embodiment. 
         FIG. 16  is a block diagram representing a functional configuration of a casting equipment monitoring system according to a third embodiment. 
         FIG. 17  is a block diagram representing a functional configuration of a diagnostic device. 
         FIG. 18  is a block diagram representing a functional configuration of a diagnosis result reception device. 
         FIG. 19  illustrates an example of map information displayed on a display portion. 
         FIG. 20  illustrates another example of map information displayed on a display portion. 
         FIG. 21  illustrates an overview of a casting equipment monitoring system. 
         FIG. 22  is a flow chart illustrating a method for monitoring casting equipment using a casting equipment monitoring system according to the third embodiment. 
         FIG. 23  illustrates an example of a report generated by a control portion of a diagnostic device. 
         FIG. 24  illustrates an example of a screen displayed on a display portion. 
         FIG. 25  illustrates another example of a screen displayed on a display portion. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Herebelow, embodiments for carrying out the casting equipment monitoring system and casting equipment monitoring method according to the present invention will be described on the basis of drawings, with reference to the attached drawings. 
     First Embodiment 
     The first embodiment will be explained with reference to the attached drawings.  FIG. 1  is a block diagram representing a functional configuration of a casting equipment monitoring system according to the first embodiment. The casting equipment monitoring system  1  comprises: casting equipment comprising a mixer  2 , a molding machine  3 , a core making machine  4 , a pouring machine  5 , a cooling machine  6 , and a shake-out machine  7 ; an information collecting device  8 ; and a diagnostic device  9 . 
     The mixer  2 , which is one of the units of casting equipment, adds a binding agent and water to green sand and kneads them to produce kneaded sand. The mixer  2  comprises a control portion  12 . The control portion  12  controls the operation of the mixer  2 . All measurement data pertaining to a kneading step in the mixer  2  is aggregated into the control portion  12 . Examples of measurement data pertaining to the kneading step include: the CB value (compactability value), which is a property of the kneaded sand; the temperature of the green sand and kneaded sand; the moisture content of the green sand and kneaded sand; and the operation sound (noise) of the mixer  2 . Such measurement data is treated as items to be inspected in the kneading step. The control portion  12  is a computer or a PLC (programmable logic controller). 
     The molding machine  3 , which is one of the units of casting equipment, molds master molds (cope and drag). The molding machine  3  comprises a control portion  13 . The control portion  13  controls the operation of the molding machine  3 . All measurement data pertaining to a master mold molding step in the molding machine  3  is aggregated into the control portion  13 . Examples of measurement data pertaining to the master mold molding step include: mechanical vibration; actuator oil pressure; blow-in air pressure (pressure in aeration); air pressure in sand tank; kneaded sand temperature; sand amount in sand tank; molten metal temperature; mold strength; compressibility; dimensional displacement; and timing. Such measurement data is treated as items to be inspected in the master mold molding step. The control portion  13  is a computer or a PLC. 
     The core making machine  4 , which is one of the units of casting equipment, molds cores. The core making machine  4  comprises a control portion  14 . The control portion  14  controls the operation of the core making machine  4 . All measurement data pertaining to a core molding step in the core making machine  4  is aggregated into the control portion  14 . Examples of measurement data pertaining to the core molding step include core sand blow-in (blowing) pressure, blow-in time, air pressure in blow tank, air pressure in blow head, and die temperature. Such measurement data is treated as items to be inspected in the core molding step. The control portion  14  is a computer or a PLC. 
     The pouring machine  5 , which is one of the units of casting equipment, pours molten metal into molds in which master molds and cores were subjected to mold assembly. The pouring machine  5  comprises a control portion  15 . The control portion  15  controls the operation of the pouring machine  5 . All measurement data pertaining to a pouring step in the pouring machine  5  is aggregated into the control portion  15 . Examples of measurement data pertaining to the pouring step include pouring flow rate, pouring time, and ladle tilting speed. Such measurement data is treated as items to be inspected in the pouring step. The control portion  15  is a computer or a PLC. 
     The cooling machine  6 , which is one of the units of casting equipment, cools molds into which molten metal was poured. The cooling machine  6  comprises a control portion  16 . The control portion  16  controls the operation of the cooling machine  6 . All measurement data pertaining to a cooling step in the cooling machine  6  is aggregated into the control portion  16 . Examples of measurement data pertaining to the cooling step include cooling initiation time, cooling completion time, ambient temperature, and air temperature. Such measurement data is treated as items to be inspected in the cooling step. The control portion  16  is a computer or a PLC. 
     The shake-out machine  7 , which is one of the units of casting equipment, separates molds into foundry sand and castings that were cast. The shake-out machine  7  comprises a control portion  17 . The control portion  17  controls the operation of the shake-out machine  7 . All measurement data pertaining to a shake-out step in the shake-out machine  7  is aggregated into the control portion  17 . Examples of measurement data pertaining to the shake-out step include: shake-out machine noise; the vibration amount of the vibration motor of the shake-out machine; the temperature of the vibration motor of the shake-out machine; and the moisture value of foundry sand after molds are subjected to shake-out with the shake-out machine. Such measurement data is treated as items to be inspected in the shake-out step. The control portion  17  is a computer or a PLC. 
     (Information Collecting Device) 
     The information collecting device  8  collects, in real time, data measured by the devices of the casting equipment (the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7 ). Specifically, the information collecting device  8  collects, in real time: measurement data aggregated into the control portion  12  of the mixer  2 ; measurement data aggregated into the control portion  13  of the molding machine  3 ; measurement data aggregated into the control portion  14  of the core making machine  4 ; measurement data aggregated into the control portion  15  of the pouring machine  5 ; measurement data aggregated into the control portion  16  of the cooling machine  6 ; and measurement data aggregated into the control portion  17  of the shake-out machine  7 . The information collecting device  8  is a data logger. 
     In the present embodiment, data from the control portions of the devices of the casting equipment is collected in one information collecting device  8 , but the same number of information collecting devices  8  as there are devices in the casting equipment may be provided to collect data from the control portions of the devices in separate information collecting devices  8 . 
     (Diagnostic Device) 
     The diagnostic device  9  uses the collected measurement data to diagnose the condition of the devices of the casting equipment and the quality of castings produced by the casting equipment.  FIG. 2  is a block diagram representing a functional configuration of the diagnostic device  9 . The diagnostic device  9  comprises a reception portion  21 , a storage portion  22 , a control portion  23 , a display portion  24 , and a transmission portion  25 . 
     The reception portion  21  receives, in real time, measurement data collected by the information collecting device  8 . The storage portion  22  stores the received measurement data. Control values corresponding to measurement data in the devices of the casting equipment and countermeasures for when there is deviation from the control values are also pre-stored in the storage portion  22 . Furthermore, the storage portion  22  stores reports generated by the control portion  23 . 
     The control portion  23  compares, in real time, collected measurement data with the control values, and upon determining that the collected data has deviated from a control value, causes the display portion  24  to display a diagnosis result (warning) indicating that there is a risk that a fault will occur. Furthermore, the control portion  23  causes the transmission portion  25  to transmit, to the device of the casting equipment that has deviated from the control value, instruction data for changing a setting condition in the device so that the control value is not exceeded. Furthermore, the control portion  23  periodically generates a report based on the collected data. 
     The display portion  24  displays the measurement data received by the reception portion  21 , a report generated by the control portion  23 , and a diagnosis result (warning). The transmission portion  25  transmits instruction data to the device of the casting equipment that has deviated from the control value. The diagnostic device  9  is a computer.  FIG. 3  illustrates an overview of the casting equipment monitoring system  1 . 
     (Method for Monitoring Casting Equipment) 
     Next, the method for monitoring casting equipment using the casting equipment monitoring system  1  according to the first embodiment will be explained.  FIG. 4  is a flow chart illustrating the method for monitoring casting equipment using the casting equipment monitoring system  1  according to the first embodiment. 
     First, the casting equipment monitoring system  1  (devices of the casting equipment) is operated (step S 101 ). Then, the casting equipment is continuously monitored until the casting equipment monitoring system  1  (devices of the casting equipment) stops (step S 102 : Yes). 
     Simultaneously with the operation of the casting equipment monitoring system  1 , the information collecting device  8  collects, in real time, data measured by the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7  (step S 103 ). 
     Next, the reception portion  21  of the diagnostic device  9  receives, in real time, the measurement data collected by the information collecting device  8  (step S 104 ).  FIG. 5  illustrates an example of measurement data received by the diagnostic device  9 . In the present drawing, measurement data collected from the molding machine  3  is illustrated not in the form of raw data, but rather in the form of edited data that is displayed on the display portion  24 . Looking at the drawing, it can be seen that pressure in aeration, which is one of the items of measurement data, is displayed. 
     Next, the control portion  23  of the diagnostic device  9  compares, in real time, the received measurement data with control values pre-stored in the storage portion  22  of the diagnostic device  9  (step S 105 ). If the control portion  23  determines that the measurement data has not deviated from a control value (step S 105 : No), data collection continues. 
     Then, the control portion  23  periodically generates a report based on the collected data (step S 106 ).  FIG. 6  illustrates an example of a report generated by the control portion  23  of the diagnostic device  9 . In the present drawing, production information such as master mold molding count and cycle time is summarized in an easily understood manner using tables and graphs based on measurement data transmitted from the molding machine  3 . The time for collecting information in order to generate a report may be arbitrary. For example, a report may be automatically generated every eight hours and stored in the storage portion  22  of the diagnostic device  9  so that an operator can check the report later on. In addition,  FIG. 7-10  illustrate other examples of reports generated by the control portion  23  of the diagnostic device  9 . 
     On the other hand, if the control portion  23  determines that the measurement data has deviated from the control value (step S 105 : Yes), the display portion  24  of the diagnostic device  9  displays a diagnosis result (warning) indicating that there is a risk that a fault will occur (step S 107 ). For example, in the measurement data collected from the molding machine  3 , if the pressure in aeration value has deviated from the lower limit of the control value, a diagnosis result (warning) is displayed indicating that there is a risk that a fault will occur in the molding machine  3 . 
     Furthermore, if the control portion  23  knows a specific method for dealing with the fault (step S 108 : Yes), the control portion  23  transmits instruction data from the transmission portion  25  of the diagnostic device  9  to the equipment (any of the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7 ) within the casting equipment in which the measurement data has deviated from the control value, the instruction data instructing the equipment to change a setting condition so that the control value is not exceeded (step S 109 ). For example, in the measurement data collected from the molding machine  3 , if the pressure in aeration value has deviated from the lower limit of the control value, instruction data that causes the supply of air to increase by a predetermined value is transmitted to the control portion  13  of the molding machine  3  such that the pressure in aeration increases and returns to the range of the control values. Note that depending on the type of control value, instruction data that stops the equipment is transmitted in some cases. 
     One of the control portions  12 ,  13 ,  14 ,  15 ,  16 ,  17  of the equipment that has received the instruction data from the diagnostic device  9  changes a setting condition in the equipment on the basis of the instruction data (step S 110 ). For example, the control portion  13  of the molding machine  3  increases the supply of air by a predetermined value on the basis of the instruction data. As a result, the pressure in aeration value again comes within range of the control values, and it is possible to obviate the occurrence of a fault due to a decrease in pressure in aeration. 
     If the control portion  23  does not know a specific method for dealing with the fault (step S 108 : No), the fault is dealt with by an operator who has checked the diagnosis result (warning) displayed on the display portion  24 , and even after a setting condition has been changed, data collection continues (step S 103 ), and the monitoring of the casting equipment by the diagnostic device  9  continues. 
     As mentioned previously, this series of operations is performed until the casting equipment monitoring system  1  (equipment of the casting equipment) stops (step S 102 : Yes). Once the casting equipment monitoring system  1  (devices of the casting equipment) stops, the monitoring of the casting equipment ends. 
     In the present embodiment, a diagnosis result (warning) is displayed on the display portion  24  when there is a risk that a fault will occur, but the diagnostic device may be configured so as to have a speaker and issue a diagnosis result (warning) as audio, and a configuration is also possible in which a diagnosis result (warning) is issued using both screen display and audio. 
     In this manner, according to the casting equipment monitoring system according to the first embodiment, the information collecting device collects, in real time, data measured by the devices of the casting equipment, and the diagnostic device compares, in real time, the collected measurement data with a control value, and displays a diagnosis result (warning) indicating that there is a risk that a fault will occur if the diagnostic device determines that the collected data has deviated from the control value. This makes it possible to detect that the condition of casting equipment is deteriorating before the casting equipment fails, or to detect that the quality of castings produced by the casting equipment is deteriorating before it becomes clear that the castings are defective products. 
     In addition, according to the casting equipment monitoring system according to the first embodiment, if the diagnostic device determines that the collected data has deviated from a control value, the diagnostic device transmits, to the equipment that has deviated from the control value, instruction data for changing a setting condition in the equipment. This makes it possible to automatically stabilize the condition of casting equipment and the quality of castings. 
     Second Embodiment 
     Next, a second embodiment of the casting equipment monitoring system according to the present invention will be explained. Note that in the second embodiment explained below, the same reference numerals are used in the drawings to designate features common to those in the first embodiment, and descriptions thereof will be omitted. In the second embodiment, diagnosis results and reports generated by a diagnostic device are transmitted to a diagnosis result reception device at a position remote from the casting equipment monitoring system, and the diagnosis result reception device gives change instructions to the diagnostic device based on diagnosis results. 
     The second embodiment will be explained with reference to the attached drawings.  FIG. 11  is a block diagram representing a functional configuration of the casting equipment monitoring system according to the second embodiment. The casting equipment monitoring system  31  comprises: casting equipment comprising a mixer  2 , a molding machine  3 , a core making machine  4 , a pouring machine  5 , a cooling machine  6 , and a shake-out machine  7 ; an information collecting device  8 ; a diagnostic device  32 ; and a diagnosis result reception device  33 . 
     The mixer  2  adds a binding agent and water to green sand and kneads them to produce kneaded sand. The mixer  2  comprises a control portion  12 . The control portion  12  controls the operation of the mixer  2 . All measurement data pertaining to a kneading step in the mixer  2  is aggregated into the control portion  12 . The control portion  12  is a computer or a PLC. 
     The molding machine  3  molds master molds (cope and drag). The molding machine  3  comprises a control portion  13 . The control portion  13  controls the operation of the molding machine  3 . All measurement data pertaining to a master mold molding step in the molding machine  3  is aggregated into the control portion  13 . The control portion  13  is a computer or a PLC. 
     The core making machine  4  molds cores. The core making machine  4  comprises a control portion  14 . The control portion  14  controls the operation of the core making machine  4 . All measurement data pertaining to a core molding step in the core making machine  4  is aggregated into the control portion  14 . The control portion  14  is a computer or a PLC. 
     The pouring machine  5  pours molten metal into molds in which master molds and cores were subjected to mold assembly. The pouring machine  5  comprises a control portion  15 . The control portion  15  controls the operation of the pouring machine  5 . All measurement data pertaining to a pouring step in the pouring machine  5  is aggregated into the control portion  15 . The control portion  15  is a computer or a PLC. 
     The cooling machine  6  cools molds into which molten metal was poured. The cooling machine  6  comprises a control portion  16 . The control portion  16  controls the operation of the cooling machine  6 . All measurement data pertaining to a cooling step in the cooling machine  6  is aggregated into the control portion  16 . The control portion  16  is a computer or a PLC. 
     The shake-out machine  7  separates molds into foundry sand and castings that were cast. The shake-out machine  7  comprises a control portion  17 . The control portion  17  controls the operation of the shake-out machine  7 . All measurement data pertaining to a shake-out step in the shake-out machine  7  is aggregated into the control portion  17 . The control portion  17  is a computer or a PLC. 
     The information collecting device  8  collects, in real time, data measured by the devices of the casting equipment (the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7 ). The information collecting device  8  is a data logger. 
     (Diagnostic Device) 
     The diagnostic device  32  uses the collected measurement data to diagnose the condition of the devices of the casting equipment and the quality of castings produced by the casting equipment.  FIG. 12  is a block diagram representing a functional configuration of the diagnostic device. The diagnostic device  32  comprises a reception portion  34 , a storage portion  35 , a control portion  36 , a display portion  37 , and a transmission portion  38 . 
     The reception portion  34  receives, in real time, measurement data collected by the information collecting device  8 , or receives instruction data from the diagnosis result reception device  33 . The storage portion  35  stores the received measurement data. Control values corresponding to the measurement data in the devices of the casting equipment are also pre-stored in the storage portion  35 . Furthermore, the storage portion  35  stores reports generated by the control portion  36 . 
     The control portion  36  compares, in real time, the collected measurement data with the control values, and if the control portion  36  determines that collected data has deviated from a control value, the control portion  36  generates diagnosis result data and causes the display portion  37  to display the generated diagnosis result data. Then, the control portion  36  causes the transmission portion  38  to transmit the diagnosis result data. When the control portion  36  receives instruction data from the diagnosis result reception device  33 , the control portion  36  causes the transmission portion  38  to transmit the instruction data to the device of the casting equipment that has deviated from the control value. Furthermore, the control portion  36  periodically generates a report based on the collected data, and causes the transmission portion  38  to transmit the report. 
     The display portion  37  displays measurement data received by the reception portion  34 , reports generated by the control portion  36 , and diagnosis results (warnings) indicating that there is a risk that a fault will occur. Note that in the present embodiment, the display portion  37  may be omitted in the diagnostic device  32 . In this case, the control portion  36  causes the transmission portion  38  to transmit the generated diagnosis result data directly. 
     The transmission portion  38  transmits diagnosis result data or reports to the diagnosis result reception device  33 , and transmits instruction data to the device of the casting equipment that has deviated from the control value. The diagnostic device  32  is a computer. 
     Note that in the present embodiment, emails are used when the diagnostic device  32  transmits diagnosis result data or reports to the diagnosis result reception device  33  and when the diagnostic device  32  receives instruction data from the diagnosis result reception device  33 , but other methods may be used. 
     (Diagnosis Result Reception Device) 
     The diagnosis result reception device  33  receives diagnosis result data or reports from the diagnostic device  32 . In addition, the diagnosis result reception device  33  gives change instructions to the diagnostic device  32  based on the diagnosis result data. The diagnosis result reception device  33  is at a position remote from the casting equipment, the information collecting device  8 , and the diagnostic device  32 .  FIG. 13  is a block diagram representing a functional configuration of the diagnosis result reception device. The diagnosis result reception device  33  comprises a reception portion  39 , a storage portion  40 , a control portion  41 , a display portion  42 , and a transmission portion  43 . 
     The reception portion  39  receives diagnosis result data or reports from the diagnostic device  32 . The storage portion  40  stores the received diagnosis result data or reports. Countermeasures for when measurement data from devices of the casting equipment has deviated from control values are also pre-stored in the storage portion  40 . 
     The control portion  41  causes diagnosis results (warnings) indicating that there is a risk that a fault will occur, or reports, to be displayed on the display portion  42  based on diagnosis result data. Furthermore, on the basis of the diagnosis result data, the control portion  41  causes the transmission portion  43  to transmit, to the device of the casting equipment that has deviated from a control value, instruction data for changing a setting condition in the device so that the control value is not exceeded. 
     The display portion  42  displays diagnosis results (warnings) or reports. The transmission portion  43  transmits instruction data to the diagnostic device  32 . The diagnosis result reception device  33  is a computer. 
     Note that in the present embodiment, emails are used when the diagnosis result reception device  33  receives diagnosis result data or reports from the diagnostic device  32  and when the diagnosis result reception device  33  transmits instruction data to the diagnostic device  32 , but other methods may be used.  FIG. 14  illustrates a catalog explaining the casting equipment monitoring system  31 . 
     (Method for Monitoring Casting Equipment) 
     Next, the method for monitoring casting equipment using the casting equipment monitoring system  31  according to the second embodiment will be explained.  FIG. 15  is a flow chart illustrating the method for monitoring casting equipment using the casting equipment monitoring system  31  according to the second embodiment. 
     First, the casting equipment monitoring system  31  (devices of casting equipment) is operated (step S 201 ). Then, the casting equipment is continuously monitored until the casting equipment monitoring system  31  (devices of casting equipment) stops (step S 202 : Yes). 
     Simultaneously with the operation of the casting equipment monitoring system  31 , the information collecting device  8  collects, in real time, data measured by the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7  (step S 203 ). 
     Next, the reception portion  34  of the diagnostic device  32  receives, in real time, the measurement data collected by the information collecting device  8  (step S 204 ). 
     Next, the control portion  36  of the diagnostic device  32  compares, in real time, the received measurement data with control values pre-stored in the storage portion  35  of the diagnostic device  32  (step S 205 ). If the control portion  36  determines that the measurement data has not deviated from a control value (step S 205 : No), data collection continues. 
     Then, the control portion  36  periodically generates a report based on the collected data (step S 206 ). The generated report is transmitted from the transmission portion  38  of the diagnostic device  32  (step S 207 ). The reception portion  39  of the diagnosis result reception device  33  receives the report (step S 208 ) and the report is displayed on the display portion  42  of the diagnosis result reception device  33 , which can be checked by an operator. 
     On the other hand, if the control portion  36  determines that the measurement data has deviated from the control value (step S 205 : Yes), the control portion  36  generates diagnosis result data and transmits the diagnosis result data from the transmission portion  38  (step S 209 ). For example, in the measurement data collected from the molding machine  3 , if the pressure in aeration value has deviated from the lower limit of the control value, diagnosis result data indicating this is transmitted. 
     When the reception portion  39  of the diagnosis result reception device  33  receives the diagnosis result data (step S 210 ), the display portion  42  of the diagnosis result reception device  33  displays a diagnosis result (warning) indicating that there is a risk that a fault will occur (step S 211 ). For example, a diagnosis result (warning) is displayed indicating that the pressure in aeration value of the molding machine  3  has deviated from the lower limit of the control value and there is a risk that a fault will occur in the molding machine  3 . 
     Furthermore, if the control portion  41  of the diagnosis result reception device  33  knows a specific method for dealing with the fault (step S 212 : Yes), the control portion  41  transmits, from the transmission portion  43  of the diagnosis result reception device  33  to the diagnostic device  32 , instruction data for the equipment (any of the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7 ) within the casting equipment in which the measurement data has deviated from the control value, the instruction data instructing the equipment to change a setting condition so that the control value is not exceeded (step S 213 ). For example, in the measurement data collected from the molding machine  3 , if the pressure in aeration value has deviated from the lower limit of the control value, instruction data instructing the supply of air to increase by a predetermined value is transmitted to the diagnostic device  32  such that the pressure in aeration increases and returns to the range of the control values. Note that depending on the type of control value, instruction data that stops the equipment is transmitted in some cases. 
     When the reception portion  34  of the diagnostic device  32  receives the instruction data from the diagnosis result reception device  33  (step S 214 ), the control portion  36  of the diagnostic device  32  transfers the instruction data from the diagnosis result reception device  33  to the equipment within the casting equipment in which the measurement data has deviated from the control value (step S 215 ). For example, instruction data is transferred to the control portion  13  of the molding machine  3 . 
     One of the control portions  12 ,  13 ,  14 ,  15 ,  16 ,  17  of the equipment that has received the instruction data from the diagnostic device  32  changes a setting condition in the equipment on the basis of the instruction data content (step S 216 ). For example, the control portion  13  of the molding machine  3  increases the supply of air by a predetermined value on the basis of the instruction data. As a result, the pressure in aeration value again comes within range of the control values, and it is possible to obviate the occurrence of a fault due to a decrease in pressure in aeration. 
     If the control portion  41  of the diagnosis result reception device  33  does not know a specific method for dealing with the fault (step S 212 : No), the fault is dealt with by an operator who has checked the diagnosis result (warning) displayed on the display portion  42 , and even after a setting condition has been changed, data collection continues (step S 203 ), and the monitoring of the casting equipment by the diagnostic device  32  continues. 
     As mentioned previously, this series of operations is performed until the casting equipment monitoring system  31  (equipment of the casting equipment) stops (step S 202 : Yes). Once the casting equipment monitoring system  31  (devices of the casting equipment) stops, the monitoring of the casting equipment ends. 
     Note that in the present embodiment, a diagnosis result (warning) is displayed on the display portion  42  of the diagnosis result reception device  33  when there is a risk that a fault will occur, but a diagnosis result (warning) may also be displayed on the display portion  37  of the diagnostic device  32 . Also, the diagnostic device  32  and/or the diagnosis result reception device  33  may be configured so as to have a speaker and issue a warning as audio. Furthermore, a configuration is also possible in which a diagnosis result (warning) is issued using both screen display and audio. 
     In this manner, according to the casting equipment monitoring system according to the second embodiment: the information collecting device collects, in real time, data measured by the devices of the casting equipment; the diagnostic device compares, in real time, the collected measurement data with a control value, and transmits a diagnosis result to the diagnosis result reception device if the diagnostic device determines that the collected data has deviated from the control value; and the diagnosis result reception device displays a diagnosis result (warning) indicating that there is a risk that a fault will occur. Consequently, even when distant from the casting equipment, it is possible to detect that the condition of the casting equipment is deteriorating before the casting equipment fails, or to detect that the quality of castings produced by the casting equipment is deteriorating before it becomes clear that the castings are defective products. 
     In addition, according to the casting equipment monitoring system according to the second embodiment, the diagnosis result reception device transmits instruction data for changing a setting condition in equipment to the diagnostic device, and the diagnostic device transfers the instruction data to the equipment that has deviated from a control value. This makes it possible to automatically stabilize the condition of casting equipment and the quality of castings even when distant from the casting equipment. 
     Third Embodiment 
     Next, a third embodiment of the casting equipment monitoring system according to the present invention will be explained. Note that in the third embodiment explained below, the same reference numerals are used in the drawings to designate features common to those in the second embodiment, and descriptions thereof will be omitted. In the third embodiment, location information data is added to the diagnosis results and the reports generated by the diagnostic device in the second embodiment and transmitted to a diagnosis result reception device at a position remote from the casting equipment monitoring system. 
     The third embodiment will be explained with reference to the attached drawings.  FIG. 16  is a block diagram representing a functional configuration of the casting equipment monitoring system according to the third embodiment. The casting equipment monitoring system  51  comprises: casting equipment comprising a mixer  2 , a molding machine  3 , a core making machine  4 , a pouring machine  5 , a cooling machine  6 , and a shake-out machine  7 ; an information collecting device  8 ; a diagnostic device  52 ; and a diagnosis result reception device  53 . 
     The mixer  2  adds a binding agent and water to green sand and kneads them to produce kneaded sand. The mixer  2  comprises a control portion  12 . The control portion  12  controls the operation of the mixer  2 . All measurement data pertaining to a kneading step in the mixer  2  is aggregated into the control portion  12 . The control portion  12  is a computer or a PLC. 
     The molding machine  3  molds master molds (cope and drag). The molding machine  3  comprises a control portion  13 . The control portion  13  controls the operation of the molding machine  3 . All measurement data pertaining to a master mold molding step in the molding machine  3  is aggregated into the control portion  13 . The control portion  13  is a computer or a PLC. 
     The core making machine  4  molds cores. The core making machine  4  comprises a control portion  14 . The control portion  14  controls the operation of the core making machine  4 . All measurement data pertaining to a core molding step in the core making machine  4  is aggregated into the control portion  14 . The control portion  14  is a computer or a PLC. 
     The pouring machine  5  pours molten metal into molds in which master molds and cores were subjected to mold assembly. The pouring machine  5  comprises a control portion  15 . The control portion  15  controls the operation of the pouring machine  5 . All measurement data pertaining to a pouring step in the pouring machine  5  is aggregated into the control portion  15 . The control portion  15  is a computer or a PLC. 
     The cooling machine  6  cools molds into which molten metal was poured. The cooling machine  6  comprises a control portion  16 . The control portion  16  controls the operation of the cooling machine  6 . All measurement data pertaining to a cooling step in the cooling machine  6  is aggregated into the control portion  16 . The control portion  16  is a computer or a PLC. 
     The shake-out machine  7  separates molds into foundry sand and castings that were cast. The shake-out machine  7  comprises a control portion  17 . The control portion  17  controls the operation of the shake-out machine  7 . All measurement data pertaining to a shake-out step in the shake-out machine  7  is aggregated into the control portion  17 . The control portion  17  is a computer or a PLC. 
     The information collecting device  8  collects, in real time, data measured by the devices of the casting equipment (the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7 ). The information collecting device  8  is a data logger. 
     (Diagnostic Device) 
     The diagnostic device  52  uses the collected measurement data to diagnose the condition of the devices of the casting equipment and the quality of castings produced by the casting equipment.  FIG. 17  is a block diagram representing a functional configuration of the diagnostic device. The diagnostic device  52  comprises a reception portion  34 , a location information storage portion  54 , a storage portion  35 , a control portion  55 , a display portion  37 , and a transmission portion  38 . 
     The reception portion  34  receives, in real time, measurement data collected by the information collecting device  8 , or receives instruction data from the diagnosis result reception device  53 . 
     Location information data of the casting equipment being monitored by the casting equipment monitoring system  51  is stored in the location information storage portion  54 . Note that the location information data may be not only location information of the casting equipment as a whole, but also location information regarding each of the devices of the casting equipment. As the format of the location information data, in some cases, information regarding the latitude and longitude where the devices are located is pre-stored, and in some cases, GPS (Global Positioning System) is integrated into the devices and GPS location information of the devices is stored. 
     In addition, if GPS has been integrated, the information collecting device  8  may periodically collect GPS location information of the devices. This makes continued monitoring possible even if a device of the casting equipment has moved for some reason. 
     Furthermore, GPS may also be integrated into the diagnostic device  52 . Even if the diagnostic device  52  is stolen, the data collected until then can be prevented from being stolen by others by setting the data within the diagnostic device  52  to be automatically erased if the diagnostic device  52  moves by at least a predetermined distance (such as 1 km). 
     The storage portion  35  stores the received measurement data. Control values corresponding to the measurement data in the devices of the casting equipment are also pre-stored in the storage portion  35 . Furthermore, the storage portion  35  stores reports generated by the control portion  55 . 
     The control portion  55  compares, in real time, collected measurement data with the control values, and causes the display portion  37  to display a diagnosis result if the control portion  55  determines that collected data has deviated from a control value. Then, the control portion  55  adds location information data of the casting equipment to the generated diagnosis result data, and causes the transmission portion  38  to transmit this data as diagnosis result data with location information. When the control portion  55  receives instruction data from the diagnosis result reception device  53 , the control portion  55  causes the transmission portion  38  to transmit the instruction data to the device of the casting equipment that has deviated from the control value. Furthermore, the control portion  55  periodically generates a report based on the collected data, adds location information data to the generated report, and causes the transmission portion  38  to transmit the report. 
     The display portion  37  displays the measurement data received by the reception portion  34 , a report generated by the control portion  55 , and a diagnosis result (warning) indicating that there is a risk that a fault will occur. Note that in the present embodiment, the display portion  37  may be omitted in the diagnostic device  52 . The transmission portion  38  transmits diagnosis result data or reports to the diagnosis result reception device  53 , and transmits instruction data to the device of the casting equipment that has deviated from the control value. The diagnostic device  52  is a computer. 
     Note that in the present embodiment, emails are used when the diagnostic device  52  transmits diagnosis result data or reports with location information to the diagnosis result reception device  53  and when the diagnostic device  52  receives instruction data from the diagnosis result reception device  53 , but other methods may be used. 
     (Diagnosis Result Reception Device) 
     The diagnosis result reception device  53  receives diagnosis result data with location information data or reports with location information data from the diagnostic device  52 . In addition, the diagnosis result reception device  53  gives change instructions to the diagnostic device  52  based on the diagnosis result data. The diagnosis result reception device  53  is at a position remote from the casting equipment, the information collecting device  8 , and the diagnostic device  52 .  FIG. 18  is a block diagram representing a functional configuration of the diagnosis result reception device. The diagnosis result reception device  53  comprises a reception portion  39 , a location information storage portion  56 , a storage portion  40 , a control portion  57 , a display portion  42 , and a transmission portion  43 . 
     The reception portion  39  receives diagnosis result data with location information data or reports with location information data from the diagnostic device  52 . 
     Location information data of casting equipment being monitored by the casting equipment monitoring system  51  is stored in the location information storage portion  56 . 
     The storage portion  40  stores received diagnosis result data with location information data or reports with location information data. Countermeasures for when measurement data from devices of the casting equipment has deviated from control values are also pre-stored in the storage portion  40 . 
     The control portion  57  causes diagnosis results (warnings) indicating that there is a risk that a fault will occur, or reports with location information data, to be displayed on the display portion  42  based on diagnosis result data with location information data. 
     Furthermore, on the basis of diagnosis result data with location information data, the control portion  57  causes the transmission portion  43  to transmit, to the device of the casting equipment that has deviated from a control value, instruction data for changing a setting condition in the device so that the control value is not exceeded. 
     The display portion  42  displays diagnosis results (warnings) or reports. In addition, when displaying a diagnosis result (warning) or a report, the location information data included in diagnosis result data with location information data or in a report with location information data is collated with the location information data stored in the location information storage portion  56 , which is displayed together therewith as map information.  FIG. 19  illustrates an example of map information displayed on the display portion  42 . In addition,  FIG. 20  illustrates another example of map information displayed on the display portion  42 . Here,  FIG. 19  shows a casting equipment monitoring system  51  built in Japan, while  FIG. 20  shows a casting equipment monitoring system  51  built across the globe. 
     The transmission portion  43  transmits instruction data to the diagnostic device  52 . The diagnosis result reception device  53  is a computer. 
     Note that in the present embodiment, emails are used when the diagnosis result reception device  53  receives diagnosis result data or reports with location information from the diagnostic device  52  and when the diagnosis result reception device  53  transmits instruction data to the diagnostic device  52 , but other methods may be used.  FIG. 21  illustrates an overview of the casting equipment monitoring system  51 . 
     (Method for Monitoring Casting Equipment) 
     Next, the method for monitoring casting equipment using the casting equipment monitoring system  51  according to the third embodiment will be explained.  FIG. 22  is a flow chart illustrating the method for monitoring casting equipment using the casting equipment monitoring system  51  according to the third embodiment. 
     First, the casting equipment monitoring system  51  (devices of the casting equipment) is operated (step S 301 ). Then, the casting equipment is continuously monitored until the casting equipment monitoring system  51  (devices of the casting equipment) stops (step S 302 : Yes). 
     Simultaneously with the operation of the casting equipment monitoring system  51 , the information collecting device  8  collects, in real time, data measured by the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7  (step S 303 ). 
     Next, the reception portion  34  of the diagnostic device  52  receives, in real time, the measurement data collected by the information collecting device  8  (step S 304 ). 
     Next, the control portion  55  of the diagnostic device  52  compares, in real time, the received measurement data with control values pre-stored in the storage portion  35  of the diagnostic device  52  (step S 305 ). If the control portion  55  determines that the measurement data has not deviated from a control value (step S 305 : No), data collection continues. 
     Then, the control portion  55  periodically generates a report with location information from the collected data (step S 306 ). A generated report with location information is transmitted from the transmission portion  38  of the diagnostic device  52  (step S 307 ). The reception portion  39  of the diagnosis result reception device  53  receives the report with location information (step S 308 ), and both the report and a map showing the position of the casting equipment for which the report was generated are displayed on the display portion  42  of the diagnosis result reception device  53 . This allows an operator to easily check the position of the casting equipment for which the report was generated.  FIG. 23  illustrates an example of a report generated by the control portion  55  of the diagnostic device  52 . 
     On the other hand, if the control portion  55  determines that the measurement data has deviated from the control value (step S 305 : Yes), the control portion  55  generates diagnosis result data with location information and transmits this data from the transmission portion  38  (step S 309 ). 
     When the reception portion  39  of the diagnosis result reception device  53  receives the diagnosis result data with location information (step S 310 ), the display portion  42  of the diagnosis result reception device  53  displays both a diagnosis result (warning) indicating that there is a risk that a fault will occur and a map showing the position of the casting equipment for which there is a risk that a fault will occur (step S 311 ). This allows an operator to easily check the position of the casting equipment for which there is a risk that a fault will occur. 
       FIG. 24  illustrates an example of a screen displayed on the display portion  42 . In the present drawing, it can be understood at a glance that an issue is occurring in the molding machine of casting equipment A. The present drawing displays the location of casting equipment A on a map of Japan, but it is also possible to specifically display the area in the casting equipment where there is an issue.  FIG. 25  illustrates another example of a screen displayed on the display portion  42 . In the present drawing, the area where an issue in the molding machine of casting equipment A is occurring can be understood at a glance. 
     Furthermore, in  FIGS. 24 and 25 , the status of casting equipment is displayed in different colors, so the condition of the casting equipment can be recognized at a glance. For example, in  FIG. 24 , if an issue occurs in casting equipment, a mark representing the location of the casting equipment changes from green to red, which allows an operator to quickly become aware that the issue has occurred. Furthermore, in  FIG. 25 , if an issue occurs in casting equipment, a mark representing the area in casting equipment where there is an issue changes from green to red, which allows an operator to quickly become aware of the occurrence of the issue as well as the position of occurrence thereof. 
     Furthermore, if the control portion  57  of the diagnosis result reception device  53  knows a specific method for dealing with the fault (step S 312 : Yes), the control portion  57  transmits, from the transmission portion  43  of the diagnosis result reception device  53  to the diagnostic device  52 , instruction data for the equipment (any of the mixer  2 , the molding machine  3 , the core making machine  4 , the pouring machine  5 , the cooling machine  6 , and the shake-out machine  7 ) within the casting equipment in which the measurement data has deviated from the control value, the instruction data instructing the equipment to change a setting condition so that the control value is not exceeded (step S 313 ). Note that, depending on the type of control value, instruction data that stops the equipment is transmitted in some cases. 
     When the reception portion  34  of the diagnostic device  52  receives the instruction data from the diagnosis result reception device  53  (step S 314 ), the control portion  55  of the diagnostic device  52  transfers the instruction data from the diagnosis result reception device  53  to the equipment within the casting equipment in which the measurement data has deviated from the control value (step S 315 ). 
     One of the control portions  12 ,  13 ,  14 ,  15 ,  16 ,  17  of the equipment that has received the instruction data from the diagnostic device  52  changes a setting condition in the equipment on the basis of the instruction data content (step S 316 ). If the control portion  57  of the diagnosis result reception device  53  does not know a specific method for dealing with the fault (step S 312 : No), the fault is dealt with by an operator who has checked the diagnosis result (warning) displayed on the display portion  42 , and even after a setting condition has been changed, data collection continues (step S 303 ), and the monitoring of the casting equipment by the diagnostic device  52  continues. 
     As mentioned previously, this series of operations is performed until the casting equipment monitoring system  51  (equipment of the casting equipment) stops (step S 302 : Yes). Once the casting equipment monitoring system  51  (devices of the casting equipment) stops, the monitoring of the casting equipment ends. 
     Note that in the present embodiment, both a diagnosis result (warning) and a map showing the position of the casting equipment are displayed on the display portion  42  of the diagnosis result reception device  53  when there is a risk that a fault will occur, but a diagnosis result (warning) may also be displayed on the display portion  37  of the diagnostic device  52 . Also, the diagnostic device  52  and/or the diagnosis result reception device  53  may be configured so as to have a speaker and issue a diagnosis result (warning) as audio. Furthermore, a configuration is also possible in which a diagnosis result (warning) is issued using both screen display and audio. 
     In this manner, according to the casting equipment monitoring system according to the third embodiment, the diagnosis result reception device displays both a diagnosis result (warning) indicating that there is a risk that a fault will occur and a map showing the position of casting equipment for which there is a risk that a fault will occur. This allows an operator to easily check the position of the casting equipment for which there is a risk that a fault will occur. 
     Note that in the first to third embodiments, the casting equipment comprises, but is not limited to, a mixer, a molding machine, a core making machine, a pouring machine, a cooling machine, and a shake-out machine. For example, the casting equipment may comprise conveyance devices such as a conveyor that conveys molds, and measurement data pertaining to the conveying step can be collected in real time by the information collecting device and diagnosed by the diagnostic device. 
     In addition, in the first to third embodiments, the information collecting device collects, in real time, the data measured by the casting equipment, but for example, if an event occurs, such as equipment failure or the occurrence of trouble in equipment, then data is additionally collected from that equipment. This is the same whether, for example, there is a failure due to human error or the occurrence of trouble due to human error. 
     In addition, in the second and third embodiments, the diagnostic device generates a diagnosis result and a report based on measurement data collected by an information collecting device, and the diagnosis result reception device receives the diagnosis result and the report. However, a configuration is also possible in which the diagnostic device transmits measurement data collected by the information collecting device directly to the diagnosis result reception device and the diagnosis result reception device generates a diagnosis result and a report based on the measurement data. 
     In addition, in the third embodiment, it is envisaged that GPS is integrated into the diagnostic device, but GPS may also be integrated into the diagnostic device in the first and second embodiments. In this case as well, even if the diagnostic device is stolen, the data collected until then can be prevented from being stolen by others by setting the data within the diagnostic device to be automatically erased if the diagnostic device moves by at least a predetermined distance (such as  1  km). 
     Various embodiments of the present invention were explained above, but the explanations above are not restrictive of the present invention, and various modifications including the deletion, addition, and substitution of structural components may be contemplated within the technical scope of the present invention. 
     REFERENCE SIGNS LIST 
     
         
           1 ,  31 ,  51  Casting equipment monitoring system 
           2  Mixer 
           3  Molding machine 
           4  Core making machine 
           5  Pouring machine 
           6  Cooling machine 
           7  Shake-out machine 
           8  Information collecting device 
           9 ,  32 ,  52  Diagnostic device 
           12 ,  13 ,  14 ,  15 ,  16 ,  17 ,  23 ,  36 ,  41 ,  55 ,  57  Control portion 
           21 ,  34 ,  39  Reception portion 
           22 ,  35 ,  40  Storage portion 
           24 ,  37 ,  42  Display portion 
           25 ,  38 ,  43  Transmission portion 
           33 ,  53  Diagnosis result reception device 
           54 ,  56  Location information storage portion