GB2037012A

GB2037012A - Computer diagnostic system

Info

Publication number: GB2037012A
Application number: GB7938544A
Authority: GB
Original assignee: Davy Loewy Ltd
Current assignee: Davy Loewy Ltd
Priority date: 1978-11-09
Filing date: 1979-11-07
Publication date: 1980-07-02

Abstract

In a method of determining the location of a fault, e.g. in an integrated forging installation 2, information corresponding to each component part of the installation and the correct operating parameters of each component part is stored in a memory 3 and a computer 1 is used to produce, on a visual display unit 5, schematic diagrams of at least part of the installation and indicate tests which are to be carried out. The operator causes the test results to be supplied to the computer, or the computer retrieves it from monitored points, and, after comparing the results with the stored information, the computer indicates on the display either where the fault lies or further schematic diagrams and tests which are to be carried out to locate where the fault lies. <IMAGE>

Description

SPECIFICATION Fault finding in an industrial installation by means of a computer.

The present invention relates to a method of, and apparatus for, determining the location of an indicated fault in an industrial installation. In many complex industrial installations, such as chemical plant and metal forming and shaping plant, the complexity and multiplicity of the equipment making up the installation is such that the location of a fault in the installation by maintenance personnel is extremely time consuming. If the fault causes the installation to be shut down, the cost of the loss of production during fault finding and repair or replacement of the faulty equipment can be extremely high. Futhermore, the complexity of the equipment in modern industrial installations is often such that locating a fault quickly and efficiently may be beyond the skill and technical experience of the maintenance personnel.

A fault diagnostic system has been proposed in which the entire industrial installation is illustrated in a fault finding manual in the form of an interconnected set of functions and sub-functions, presented in the form of block diagams. Each block diagram shown in the manual will indicate all the inputs and outputs for each function block and will refer to test points by which each input or output may be tested. Also contained in the manual will be the method of testing with the test results which should be present under normal conditions. By performing checks as instructed, the maintenance personnel are taken step-by-step through the block functions diagrams until the part of the installation containing the fault in reached and which part is replaceable or within the ability of the maintenance personnel to repair.

A fault finding manual, as described above, for a large installation can be of very large physical size which is not easily portable and indeed some of the information which should be contained in the manual, for example drawings of component parts, may by necessity have to be stored at a location away from the manual where it can only be obtained by the personnel on specific request.

The physical size of the manual and the fact that it may not contain all the information that is required are some of the disadvantages of this fault diagnostic system.

It is an object of the present invention to provide a method of fault finding in an industrial installation by employing a computer which at least partially overcomes the disadvantages referred to above.

According to the present invention, in a method of determining the location of a fault in an industrial installation, information corresponding to each component part of the installation and the correct operating parameters of each component part is stored in a memory device, and when the presence of a fault somewhere in the installation is indicated an operator causes a computer to use the stored information and produce on a visual display unit schematic diagrams of parts of at least part of the installation and to indicate test which ere to be carried out, the test results are supplied to the computer, and the computer compares the results of the tests with the stored information and either indicates on the display device in which component the fault lies or systematically indicates on the display unit further schematic diagrams and tests which are to be carried out to locate the component in which the fault lies.

The information stored in the memory device is conveniently in such a form that the visual display unit initially displays a block diagram of the installation with tests which are to be undertaken.

Dependent upon the results of the tests, the computer is able to determine in which part of the installation the fault lies and a display of a block diagram of this part is then displayed on the display unit. Further tests which are to be undertaken are also indicated on the display unit.

When the results of these tests are supplied to the computer, the computer may be able to indicate in which component of equipment the fault lies or it may be necessary to display schematic diagrams of one or more components of the installation and tests which are required in order to eventually determine in which component the fault lies.

The invention enables an operator to systematically work through the equipment of a complex industrial installation until an indicated fault is found. The operator supplies the 'information to the various tests which are indicated on the visual display unit until the computer is able to determine in which component the fault lies. The component can then be repaired or replaced.

In order that the invention may be more readily understood it will now be described, by way of example only, with reference to the accompanying drawings, in which:~ Figure 1 shows diagrammatically the apparatus for fault finding in an industrial installation, Figure 2 is a typical display on a visual display device, and Figure 3 is a display on a visual display device following the display of Figure 2.

Referring to Figure 1, a supervisory computer 1, for use with an industrial installation 2, has access to a memory device 3 and is connected to a printer 4, a visual display device VDU 5 and to an input keyboard 7. The keyboard and the VDU may be located on the control desk for the installation.

Information concerning the schematic diagrams of the equipment of the industrial installation and the operating parameters of the components of the installation are stored in the memory device in a form which enables the information to be readily presented in the VDU.

A particular, but not sole, application of the invention is to the location of a fault in an integrated forging installation comprising a forging press and one or more ingot manipulators.

Additional equipment such as a tool guide, and anvil slide and an ingot car may be included.

When a fault somewhere in the installation 2 is indicated, as for example by a visual or audible alarm, an operator causes a block diagram of either the entire installation or of a particular part thereof to be indicated on the visual display unit depending upon whether or not it is clear in which part of the installation the fault lies. The block diagram may be displayed in colour with say the electrical connections shown in one colour and hydraulic connections in a different colour. A simplified block display of the entire installation is shown in Figure 2. This display indicates interconnected equipment F1-F7. References TP 1-TP20 indicate the test points on the equipment where various test measurements or visual checks are to be made. Referencesfand g indicate questions indicated on the display which have to be answered by the operator.The operator obtains the test information required for TP1-TP20 and introduces then into the computer by way of keyboard 7, unless the test information is obtainable by the computer from monitored points. The questions fand g are answered by the operator and the information supplied to the computer. The computer compares the information stored in the memory device 3 with the information supplied by way of test results TP 1 -TP20 and considers the answers to the questions fand g and determines in which equipment the fault lies. Say that the computer determines that the fault lies in equipment F4, the block diagram of equipment F4 is then displayed on the display unit as shown in Figure 3.

Equipment F4 has individual components 4.1 to 4.1 1 and references TP indicate positions where test information is required and land m indicate questions which are to be answered. The letter E, H or M before the component number indicates that the component is mainly electrical, hydraulic or mechanical respectively.

The operator supplies the test results from positions TP and supplies the answers to questions land m. This information is supplied to the computer. From a comparison of this information and that previously stored the computer is able to determine in which component the fault lies. The block diagram of this component is then indicated on the display unit. If this component is a replaceable module, a message on the VDU will indicate this fact to the operator who can then arrange for the replacement to be made, otherwise the abovedescribed process is repeated until the fault is localised to a replaceable module.

Referring again to Figure 2, this block diagram represents the function of the entire installation and as such shows all inputs and outputs to the installation. In the example referred to above, F1 is the forge supervision function, F2 is the system control function, F3 is the sequence control function, F4 is the manipulator control function, F5 is the press control function, F6 is the ingot car control function controlled by F3, and F7 is all the power supplies supplying power to F1 to F6.

Some of the test points, e.g. TP 1, TP2, TP6 and TP 13, are checks on the data transferring along the data limbs, whereas other test points, e.g. TP3 and TP4, are checks on the performance of the machinery of the installation. Some of these checks can be made visually, for example is a motor rotating or a ram operating, whereas the data transfer checks are made by the computer it#self.

In Figure 3 is shown the block diagram of function F4 - the manipulator control function.

The function shown in this figure indicates whether the function is mainly electrical, hydraulic or mechanical. For example, E4.1 indicates a largely electrical function and M4.9 indicates a largely mechanical function. This means that the operator can seek help from a maintenance man who specialises in the appropriate skill if the fault is indicated to in one of these functions.

Each function indicates whether or not it is the lowest level to which it can be broken down in the fault finding procedure. For example, function 4.2 shown in Figure 3 represents the long travel control of the manipulator. This in turn can be shown to have functions 4.2.1 to 4.2.8 and some of these functions can be represented by further functions E9, functions 4.2.8 can be divided into components 4.2.8.1 to 4.2.8.8. When each component block is displayed on the VDU it is indicated whether or not this component is a lowest level component, i.e. one which is a replaceable module. If it is a replaceable module, the VDU displays the manufacturers or installation part number so that a replacement can readily be obtained from stock for fitting into the installation.

The method of this invention enables an industrial installation to be kept operating as long as possible by ensuring that faults which cause the installation to be shut down are located as quickly as possible. In many cases a fault can be located without having to shut the installation down, and the down time is only represented by the time required to remove and replace the faulty component. By systematically checking the installation as indicated by the computer when a fault does occur, the fault can be located as quickly as possible. Futhermore, when a fault has been located it can be corrected by maintenance personnel of the appropriate skill since the computer will indicate in which component the fault lies and the appropriate maintenance engineer can be called upon.

Claims

1. A method of determining the location of a fault in an industrial installation, in which information corresponding to each component part of the installation and the correct operating parameters of each component part is stored in a memory device, and when the presence of a fault somewhere in the installation is indicated an operator causes a computer to use the stored information and produce on a visual display unit schematic diagrams of parts of at least part of the installation and to indicate tests which are to be carried out, the test results are supplied to the computer, and the computer compares the results of the tests with the stored information and either indicates on the display device in which component the fault lies or systematically indicates on the display unit further schematic diagrams and tests which are to be carried out to locate the component in which the fault lies.

2. A method as claimed in claim 1, in which the schematic diagrams indicate test points on the installation where checks are to be made and the information supplied to the computer.

3. A method as claimed in claim 2, in which at least some of the checks are made at points continuously monitored by the computer.

4. A method as claimed in claim 2, in which at least some of the checks are made by the operator and information is introduced by the operator into the computer.

5. A method as claimed in any preceding claim, in which the schematic diagrams of various components indicate whether the components are of mainly electrical, mechanical or hydraulic form.

6. A method as claimed in claim 5, in which electrical, mechanical and hydraulic components are indicated on the schematic diagrams in different colours.

7. A method as claimed in any preceding claim, as applied to a forgjng installation.

8. Apparatus for use in determining the location of a fault in an industrial installation comprising a memory device programmed to store information corresponding to each component part of the installation and the correct operating parameters of each component part, a visual display unit, a computer having acess to the memory device and means for introducing information into the computer other than from the memory device, said computer being arranged to compare information supplied thereto other than from the memory device with information from the memory device and to indicate on the visual display unit schematic diagrams of at least part of the installation and to indicate tests which are to be carried out, the results of said tests being introduced into the computer other than from said memory device and the computer thereafter indicating in which component the fault lies.