MITSUBISHI ELECTRIC Veranderingen ten goede

Detecting machine defects

Take proactive steps to maintain flawless operation

Detecting machining defects early is crucial to maintaining quality and reducing waste. Yet, many issues – such as weak bonding in the metal fin caulking process – aren’t immediately visible. At first product may seem fine, however, defects can occur when the bonding isn't as robust as it should be, leading to issues like metal fins detaching in later stages.

The challenge lies in identifying these hidden faults before they impact production on a larger scale. How can manufacturers stay ahead of such issues? The answer lies in predictive maintenance, which enables real-time monitoring and early detection of defects, preventing faulty products from reaching the next stage.

Use proactive solutions based on artificial intelligence

By employing AI-driven tools such as the MELSOFT MaiLab in conjunction with the MELIPC industrial-use PC, manufacturers can monitor the caulking process in real-time. 

The process consists of several key stages:

1. Learning normal operations: the system records and analyses waveform data of press loads during standard, defect-free operations.

2. Establishing diagnostic rules: AI processes this data to identify patterns associated with optimal bonding, creating diagnostic rules based on these patterns.

3. Real-time monitoring: during production, the system continuously collects press load data and compares it against the established diagnostic rules.

4. Detecting anomalies: if the system identifies deviations indicating potential bonding weaknesses, it immediately signals these issues. To do this, it checks whether or not the real-time data provided is similar to the normal pattern

5. Immediate response and feedback to equipment: upon detecting a defect, the system can trigger actions such as halting the equipment to prevent the defective product from advancing further in the production line.

This AI-driven approach ensures that bonding defects are caught early, preventing faulty products from reaching subsequent stages and maintaining overall production quality.

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