JP2000148233A - Remote maintenance management device for asphalt plant - Google Patents

Abstract

PROBLEM TO BE SOLVED: To take measures immediately in case of trouble and to support the economical operation of the plant by enabling a maker side to grasp abnormality of the asphalt plant and its sign. SOLUTION: A reference state data storage means 14 of a plant monitor terminal 3 of a plant controller 2 is previously stored with reference state data of respective devices in the normal operation of the plant and operation state data of the plant outputted through the operations of many sensors and various switched in the plant operation are detected and stored in a state data storage means 13. Then a comparing means 15 compares the latest state data with the reference state data and when detected state data exceeds the permissible limit of the reference state data, the plant monitor terminal 3 automatically sends alarm data to a remote maintenance center device by a data transmitting means, so that the alarm data is outputted and displayed on the side of the remote maintenance center device.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plant monitoring terminal for monitoring the operation status of an asphalt plant and a remote maintenance center device, which are connected by communication means. The present invention relates to an apparatus for remotely managing and managing a plant.

[0002]

2. Description of the Related Art In an asphalt plant, aggregates are cut out at a desired ratio from an aggregate hopper for storing aggregates such as crushed stone and sand for each type, and heated by a dryer having a burner. The asphalt mixture is temporarily stored in storage bins for each particle size, a predetermined amount of aggregate having various particle sizes is weighed and mixed into a mixer based on the composition of the asphalt mixture to be produced, and molten asphalt is added to mix. Has been manufactured.

The asphalt plant comprising a series of systems for supplying, heating, measuring and mixing the aggregate is also highly automated by employing a microcomputer.

[0004]

However, when the asphalt plant is highly automated as described above, a trouble that cannot be dealt with by the operator may occur. The side may not be able to judge the cause of the trouble just by listening to the progress of the trouble or the signs of the trouble from the operator, and may not be able to respond promptly.

[0005] In the case of a trouble in the control system, not only the sequence program of the sequencer mounted in each user's plant is common, but also the manufacturer receives the trouble report and searches for the drawing of the user. In order to check and improve the program, a technician goes to a plant factory to change the program, and it may take time to resolve the trouble.

It is considered that there are some signs before the occurrence of this trouble, but it is considered that major troubles can be reduced if the signs can be grasped in advance by the manufacturer.

[0007] Furthermore, asphalt plants can be operated efficiently by maintaining each device in a well-balanced manner. At each plant factory, efforts are being made to investigate fuel efficiency, etc. and to operate efficiently and economically. However, it collects all operational status data of the plant in detail,
Analyzing the data to evaluate whether or not the plant is operating under optimal conditions requires some labor and experience, and thus has some difficulties.

[0008] In view of the above, the present invention enables a manufacturer to grasp a plant abnormality and its signs, and to promptly deal with a trouble in the event of a trouble, thereby supporting economical operation of the plant. An object of the present invention is to provide a remote maintenance management device for an asphalt plant.

[0009]

In order to solve the above-mentioned problems, the present invention relates to a remote maintenance management device for an asphalt plant according to claim 1, which is connected to a plant control device for an asphalt plant. A plant monitoring terminal for monitoring the operation status and a remote maintenance center device are connected by communication means, and the plant monitoring terminal is output by operating a number of sensors and various switches of a plant control device disposed on each device of the plant. Reference state data storage means for pre-storing reference state data for maintaining proper operation of plant operation state data comprising various signals, and fetching and sequentially storing the state data at a predetermined cycle during plant operation. Status data storage means, comparing the status data with the reference status data, Comparing means for determining whether or not the state data exceeds an allowable limit; and data transmitting means for automatically transmitting alarm data to the remote maintenance center apparatus when the allowable limit is exceeded. The apparatus is characterized by comprising data output means for outputting alarm data received from the plant monitoring terminal, and state data collecting means for collecting state data accumulated on the plant monitoring terminal side.

According to a second aspect of the present invention, in the remote maintenance management device for an asphalt plant, the remote maintenance center device remotely manages a sequence program of a sequencer mounted on a plant control device via communication means. Is provided.

According to a third aspect of the present invention, there is provided a remote maintenance management device for an asphalt plant, wherein the remote maintenance center device includes state data analysis means for analyzing an operation status from status data collected from the plant. And a report creation means for outputting the result as an evaluation report.

[0012]

According to the asphalt plant remote maintenance management device according to the first aspect of the present invention, first,
A plant monitoring terminal is provided in a plant control device of an asphalt plant, and the plant monitoring terminal stores in advance various kinds of reference state data serving as references for realizing proper operation of plant operation state data.

At the time of plant operation, plant operation status data consisting of a large number of sensors disposed in each device and various signals output by operating various switches of the plant control device is taken into the plant monitoring terminal at a predetermined cycle, and the status data is acquired. The state data is sequentially stored in the storage means, and the state data is compared with the reference state data previously stored by the comparison means. If the status data exceeds the permissible limit with respect to the reference status data and there is an abnormality or a sign thereof, alarm data is transmitted from the plant monitoring terminal to the maker's remote maintenance center device via the communication means by the data transmission means. Call automatically. When the remote maintenance center receives this alarm data, it immediately outputs it to the data output means.

By the output of the alarm data, the remote maintenance center side can immediately recognize the user name and the abnormal state of the transmission of the plant abnormality, determine whether the abnormality needs to be dealt with immediately, If it is necessary to respond to the problem, the user is informed of the fact and a corresponding measure is taken. At this time, in order to know the degree of abnormality of the plant in detail, the state data of the plant accumulated in the state data storage means of the plant monitoring terminal is collected by the remote maintenance center device side via the communication means, and the state data is analyzed. The degree of abnormality can be accurately determined. Even if not at the time of the transmission of an abnormality, the operation status of the plant can be grasped by collecting the status data of the plant with the remote maintenance center device, so that the manufacturer of the remote maintenance center device can notify the user about the plant maintenance management. It is very convenient because I can give appropriate advice.

According to the asphalt plant remote maintenance management device of the second aspect, the sequence program of the sequencer mounted on the user's plant control device is communicated using the sequence maintenance management device of the remote maintenance center device. When the plant fails, the program can be immediately projected and checked without searching for materials stored in the maker when the plant fails, and if the program is modified, the program can be transmitted to the plant control device side to rewrite the program. As a result, the efficiency of maintenance work can be increased without the need for a technician to move.

According to the third aspect of the present invention, the status data of the plant stored in the status data storage means of the plant monitoring terminal is collected by the remote maintenance center device via the communication means. Then, the collected state data of the plant is analyzed by the state data analysis means, and the result of the analysis by the report creation means is output as an evaluation report. This makes it possible to evaluate whether the equipment of the plant is operating in an appropriate state and how efficient and economical operation is being performed, and submit the results to the user as an evaluation report. This will be useful for economical operation management and maintenance management of the plant.

[0017]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows a remote monitoring center device 1 for remote monitoring and a plant monitoring terminal 3 connected to a plant control device 2.
And an integrated digital communication network (ISD)
It is the figure connected by N) 4.

The remote maintenance center apparatus 1 is composed of a personal computer comprising a main body control section 5, an operation section 6 provided with a keyboard operated by an operator, a display section 7 for displaying various data, a printer 8, and the like.

Each of the remote maintenance center device 1 and the plant monitoring terminal 3 has a terminal adapter (TA) 9 which is necessary for connecting a normal analog telephone, facsimile or the like to the integrated digital communication network 4. It is a device that converts the protocol. The terminal adapter 9 has a digital line connection device (DS) for connecting digital equipment to the integrated digital communication network 4.
U) 10, and the digital line connection device 10 has a communication speed conversion function and an overvoltage protection function.

Then, the remote maintenance center apparatus 1 and the plant monitoring terminal 3 are connected via the terminal adapter 9 via the integrated digital communication network 4 so that information such as voices, images, and various maintenance data can be communicated at a high speed. And

FIG. 2 is a block diagram of data processing means provided in the plant monitoring terminal 3. Operation state (operating state) signals of the plant, which are detected by a large number of sensors attached to the plant, are fetched at predetermined intervals via the operation panel 11 and the power panel 12, which are the plant control device 2, and state data is stored as state data. Means 13 are sequentially stored and accumulated.

When the operation state signal of the plant is taken in, the on / off signal of the limit switch and the like and other signals from the digital equipment are taken as it is, and the analog signal such as the material temperature, the weighing value and the drive current value is taken into the plant control device. The digital signal is taken in by the A / D converter in 2. In addition, the set values input to the operation panel 11 and the on / off states of various operation switches are also taken in at the same time.

When operating the plant, the reference state data storage means 14 stores reference state data serving as a reference for judging an appropriate state if the state of each device is within this range.

The comparing means 15 stores the status data storing means 1
3, the latest state data among the state data sequentially stored and stored is compared with the reference state data stored in the reference state data storage means 14, and whether or not the state data exceeds the allowable limit with respect to the reference state data is determined. It has a function of determining whether

The data transmission means 16 receives a request for transmission of alarm data from the alarm data storage means 17 when the comparison means 15 determines that the allowable limit is exceeded, and a request for maintenance request data from the remote maintenance center device 1. Sometimes, the status data is sent from the status data storage means 13 to the remote maintenance center device 1.

The data receiving means 18 is a maintenance request data which is a required item of status data to be grasped when more detailed status data or the like is to be grasped from the remote maintenance center device 1 which has received the alarm data to the plant monitoring terminal 3. Is stored in the maintenance request data storage means 19.

The data control means 20 controls the storage means and the comparison means to transfer data and perform various operations.

On the other hand, as shown in FIG. 3, the data processing means on the side of the remote maintenance center device 1 includes the data receiving means 21 for receiving alarm data and status data transmitted from the plant monitoring terminal 3, and receives the data. A data output unit 22 for displaying alarm data on the display unit 7 is provided. The remote maintenance center device 1 has a plant monitoring terminal 3
And a data transmission unit 24 for transmitting the input maintenance request data to the plant monitoring terminal 3 side.

Further, there is provided a state data collecting means 25 for collecting the state data sequentially stored and accumulated in the state data storing means 13 of the plant monitoring terminal 3, and the collected state data is appropriately and efficiently or economically collected. State data analysis means 26 for analyzing whether a proper operation is possible
And a report creating means 27 for creating a report as to whether the plant can be operated in an appropriate state from the analyzed state data.

Reference numeral 28 denotes state data storage means for storing and storing the received state data, and reference numeral 29 denotes data control means for transferring the above-mentioned data and controlling the above-mentioned means.

FIG. 4 shows a plant monitoring terminal 3 connected to a remote maintenance center device 1 for remote monitoring and a plant control device 2.
And a remote maintenance center device 1 ′ for sequence maintenance is connected to the operation panel 11, which is the plant control device 2, by the same general digital communication network as the communication means. The remote maintenance center device 1 'is similar to the remote maintenance center device 1 described above, and includes a main body control unit 5' and an operation unit 6 'having a keyboard and the like operated by an operator.
Display unit 7 'for displaying various data and printer 8'
And the like.

On the other hand, the operation panel 11 on the plant control device 2 side
In the figure, a sequencer (PLC) 30 in an operation panel 11 is connected to a terminal adapter 9 via a modem 31. Then, the remote maintenance center device 1 'reads and displays the sequence program (ladder diagram) of the sequencer 30 of the plant control device 2 on the remote maintenance center device 1' side via communication means. A sequence maintenance / management unit 32 called a PC loader is provided for improving or sending the improved sequence program to the sequencer 30 again via the communication unit.

The above-described units of the remote maintenance center devices 1 and 1 'and the plant monitoring terminal 3 are constituted by hardware and software for operating the respective units.

Next, a procedure of monitoring the status of the plant by the plant monitoring terminal 3 and grasping the status and the like by the remote maintenance center device 1 in the remote maintenance management device having the above configuration will be described with reference to the flowchart of FIG. I do. In the figure, S1 to S17 represent steps of each processing procedure.

First, as an initial setting in the plant monitoring terminal 3, the operating state of each device when the plant is operating in a preferable state and the plant state data detected by various sensors are set as reference state data. The data is stored in the data storage means 14 (S1).

When the operation of the plant is started (S2),
The data control means 20 of the plant monitoring terminal 3 functions to start the process of capturing the status data indicating the operation state of the plant, and first, determines whether or not there is an interrupt signal for capturing the status data generated at a predetermined cycle. (S3) If there is no interrupt signal, the process waits for an interrupt signal. If there is an interrupt signal, status data indicating the operation of various sensors attached to the plant and the operation of the plant control device 2 are fetched via the plant control device 2, and the state data is set to the state. Data storage means 13
(S4).

Each time the fetching of the state data of the plant is completed, the comparing means 15 sets the state data storing means 1
3 is compared with the reference state data previously stored in the reference state data storage means 14 (S5), and whether the latest state data exceeds the allowable limit for the reference state data is determined. It is determined whether or not the state data in the state data storage means 13 has been updated to the latest state data at this point (S7). In this case, the process returns to step S3 to wait for the update. If the update has been performed, the process returns to step S5 to proceed to the comparison of the updated state data. If the latest status data exceeds the permissible limit with respect to the reference status data, the alarm data storage unit 17 determines, for the device exceeding the permissible limit, the terminal code of the plant monitoring terminal 3 and the alarm content. The alarm data is transmitted to the remote maintenance center device 1 by the data transmission means 16 (S8).

The remote maintenance center device 1 receives the alarm data transmitted via the communication means by the data receiving means 21 (S9), adds the reception date and time to the alarm data, and outputs the data by the data output means 22, for example. As shown in FIG. 6, the reception date and time, the terminal code, and the contents of the alarm are displayed in a list on the display unit 7, and at the same time, an alarm is output (S10) to notify the operator of the alarm.

When the status data of the plant monitoring terminal 3 is to be read from the remote maintenance center device 1 based on the above alarm data in order to know the operating status of the plant in more detail, as shown in the flowchart of FIG. Then, the name of the device to be maintained and other maintenance request data input by the maintenance request data input unit 23 for the device for which the alarm has been transmitted are transmitted to the plant monitoring terminal 3 by the data transmission unit 24 (S11). On the plant monitoring terminal 3 side, the maintenance request data is received by the data receiving means 18 (S12), stored in the maintenance request data storage means 19 (S13), and the corresponding status data is transmitted by the data transmission means 16 to the remote maintenance center device 1 (S13).
(S14), which is received by the data receiving means 21 of the remote maintenance center device 1 (S15), stored in the status data storage means 28 (S16), and displayed on the display unit 7 by the data output means 22. The data is output to the printer 8 or the like (S17).

In this way, the plant monitoring terminal 3 is in a state where the operation state of the plant or the operation of the plant control device 2 is out of the appropriate operation range, for example, if the temperature of the material or the gas temperature becomes too high or too low. , The drive current of the motor exceeds the rated current, the plant control device 2 does not output the drive signal of the solenoid valve or power, or the condition that the operation signal of the limit switch cannot be obtained is detected. Alarm data is automatically transmitted from the plant monitoring terminal 3 side to the remote maintenance center device 1, and the remote maintenance center device 1 displays alarm data such as date and time, plant identification data, device name, and alarm content on the display unit 7. You can check with.

As a result, it is possible to quickly know that an abnormality or a sign has occurred in the operation of the plant, and the remote maintenance center device 1 sends a maintenance request to the target plant monitoring terminal 3 based on the alarm data. Publish data,
In more detail, the status data of the plant or the plant control device 2 on the plant monitoring terminal 3 side is read and displayed on the display unit 7 or output to the printer 8 to quickly grasp abnormalities and their signs, and perform proper maintenance management. It can be carried out.

Also, even if there is no abnormality in the plant, the remote maintenance center can evaluate whether the plant is operating properly and effectively. FIG. 8 will be described. In the figure, S20 to S25 represent steps of each processing procedure.

First, the status data collection means 25 of the remote maintenance center device 1 passes through the data transmission means 24 and the integrated digital communication network 4 which is a communication means, and the plant monitoring terminal 3
The state data collection request data is transmitted to the side (S20).

The plant monitoring terminal 3 receives the status data collection request data by the data receiving means 18 (S2).
1) and the state data stored and stored in the state data storage unit 13 as data indicating the history of the operating state of the plant by the data transmission unit 16 by the remote maintenance center device 1.
(S22). On the remote maintenance center apparatus 1 side, the status data is received by the data receiving means 21 (S
23), this state data is stored in the state data storage means 28 (S24), and the state data analysis means 26 checks whether each device of the plant is in an appropriate state, whether efficient and economical operation is possible, etc. , Analyze the state data (S
25).

For example, as state data analysis means, software for analysis such as operation status management, maintenance management, or shipping status management and cost management is provided. For example, regarding the operation status management software, a list shown in FIG. The software for efficiency evaluation shown in the side column corresponds to it. And, thereby, the performance operation rate, the time operation rate, the dryer heat efficiency, the dust collection efficiency, the dedusting effect, the fuel efficiency, the shipping material loss, the shipping efficiency, the performance efficiency, which are shown in the vertical columns corresponding to the circles in the list, Items such as the power consumption rate are analyzed and evaluated.

Then, the operation status of the plant analyzed and evaluated by these means is output as an evaluation report (S2).
6). As an output method, an explanation of a radar chart or an analysis result as shown in FIG. 10 and an evaluation report or the like in which advice such as future measures are compiled as a report are displayed on a display device or output to a document by a printer. can do.

Next, a procedure in a case where it is necessary to view or modify a sequence program of the operation panel 12 or the like of the plant control apparatus 2 due to a plant failure or the like will be described with reference to FIG.
This will be described based on the flowchart shown in FIG. In the figure, S3
0 to S34 represent the steps of each procedure.

First, the sequence maintenance management means 32 provided in the remote maintenance center apparatus 1 'for sequence maintenance shown in FIG. 4 converts the sequence program of the sequencer 30 mounted on the operation panel 11 of the plant control apparatus 2 into the remote maintenance center. The data is read into the device 1 via the communication means (S3
0), a ladder diagram of the sequence is displayed on the display device 7 'or output to the printer 8' (S31), and the contents are checked or improved (S32). If the program needs to be improved, the program is transmitted to the original sequencer 30 via the communication means (S33), and the recovery or improvement work is completed (S3).
4). When transmitting an improved sequence program, only the transmission operation of step S33 may be performed.

As described above, the sequence program of the sequencer 30 mounted on the plant control apparatus 2 of the user can be viewed through the communication means using the sequence maintenance management means 32 of the remote maintenance center apparatus 1 '. The program is immediately projected and checked without searching for stored materials. If the program is modified, the program can be transmitted to the plant control device 2 and the program can be rewritten. Can be increased. The sequence maintenance management means 32 can be provided in the remote maintenance center apparatus 1 for remote monitoring. However, it is better that the remote maintenance center apparatus 1 can always receive alarm data. It is preferable that each function be provided.

In this embodiment, an integrated digital communication network (ISDN) has been described as an example of communication means for connecting the remote maintenance center device 1 and the plant control device 2. However, the communication device is connected to a public line network via a modem. Of course, connection can be made, and a proper selection may be made according to the scale and content of the maintenance management.

Further, although the plant monitoring terminal 3 is provided separately from the plant control device 2, it goes without saying that the plant control device 2 may have the function of the plant remote monitoring terminal 3.

[0053]

As described above, according to the remote maintenance management device for asphalt plant according to claim 1 of the present invention,
A plant monitoring terminal connected to a plant control device of an asphalt plant to monitor the operation status of the plant and a remote maintenance center device are connected by communication means, and the plant monitoring terminal has a large number of sensors arranged in each device of the plant. Reference state data storage means for storing in advance reference state data for maintaining proper operation of plant operation state data consisting of various signals output by operating various switches of the plant control device, A state data storage unit for fetching each of the state data in a cycle, sequentially storing and accumulating the state data, and comparing the state data with the reference state data to determine whether the state data exceeds an allowable limit with respect to the reference state data. Means of comparison;
Data transmission means for automatically transmitting alarm data to the remote maintenance center device when the allowable limit is exceeded, while the remote maintenance center device has data output means for outputting alarm data received from the plant monitoring terminal, A status data collection unit that collects status data stored in the plant monitoring terminal is provided, so that the remote maintenance center of the manufacturer can immediately grasp the abnormalities and signs of the user's plants scattered around the country, It is very convenient because appropriate advice can be given even before and after the problem occurs.

According to the asphalt plant remote maintenance management device of the second aspect, the remote maintenance center device remotely manages a sequence program of a sequencer mounted on the plant control device via communication means. The system has a sequence maintenance management unit to perform the sequence program of the sequencer mounted on the user's plant control device so that the sequence program can be viewed via the communication unit. If the program is modified and the program is modified, the program can be transmitted to the plant control device and the program can be rewritten, so that the efficiency of maintenance work can be improved without the need for a technician to move.

According to the third aspect of the present invention, the remote maintenance center device includes state data analysis means for analyzing an operation status from status data collected from the plant, and an analysis result. And a report creation means for outputting the evaluation report as an evaluation report, so that the state data of the collected plant is analyzed in the state data to check whether each device of the plant is operating in an appropriate state,
In addition, it is possible to evaluate how efficient and economical operation is being performed, and submit the results to the user as an evaluation report, making it easier to economically operate and maintain the plant. There are advantages.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram showing one embodiment of a remote maintenance management device for an asphalt plant according to the present invention.

FIG. 2 is a configuration diagram of data processing means on the plant control device side.

FIG. 3 is a configuration diagram of data processing means on the remote maintenance center device side.

FIG. 4 is a schematic configuration diagram showing another embodiment of a remote maintenance management device for an asphalt plant according to the present invention.

FIG. 5 is a flowchart illustrating a data processing procedure.

FIG. 6 is a display screen diagram showing an output example of alarm data.

FIG. 7 is a flowchart illustrating a data processing procedure.

FIG. 8 is a flowchart illustrating a data processing procedure.

FIG. 9 is a list showing data analysis software and output items.

FIG. 10 is a radar chart showing an output example of data analysis software.

FIG. 11 is a flowchart illustrating a sequence maintenance procedure.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Remote maintenance center apparatus (for remote monitoring) 1 '... Remote maintenance center apparatus (for sequence maintenance) 2 ... Plant control apparatus 3 ... Plant monitoring terminal 4 ... Integrated digital communication network (ISDN) 13 ... State data storage means 14 ... Reference state data storage means 13 State data storage means 15 Comparison means 16 Data transmission means 17 Alarm data storage means 18 Data reception means 19 Maintenance data storage means 20 Data control means 21 Data reception means 22 Data output unit 23 Maintenance request data input unit 24 Data transmission unit 25 State data collection unit 26 State data analysis unit 27 Report creation unit 28 State data storage unit 29 Data control unit 30 Sequencer (PLC) 32: Sequence maintenance management means

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Claims (3)

[Claims] A plant monitoring terminal connected to a plant control device of an asphalt plant to monitor the operation status of the plant and a remote maintenance center device are connected by communication means, and the plant monitoring terminal is connected to each device of the plant. Reference state data storage means for storing in advance reference state data for maintaining proper operation of plant operation state data consisting of various signals output by operating a number of sensors and various switches of the plant control device, State data storage means for fetching and sequentially storing the state data at predetermined intervals during plant operation, and comparing the state data with the reference state data to determine whether the state data exceeds an allowable limit for the reference state data Comparing means for judging whether or not the remote maintenance center device The remote maintenance center device includes a data output unit that outputs alarm data received from the plant monitoring terminal, and a status data that collects status data stored in the plant monitoring terminal. A remote maintenance management device for an asphalt plant, comprising a collection unit. 2. The remote maintenance center device according to claim 1, further comprising a sequence maintenance management unit for remotely performing maintenance management of a sequence program of a sequencer mounted on the plant control device via a communication unit. The asphalt plant remote maintenance management device as described in the above. 3. The remote maintenance center device includes state data analysis means for analyzing an operation state from state data collected from a plant, and report creation means for outputting an analysis result as an evaluation report. The remote maintenance management device for an asphalt plant according to claim 1 or 2, wherein: