JP2007102388A - Maintenance support device, maintenance support method, maintenance support system, controller, and control method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce loss due to the non-operation of a facility of a user by performing quick cause investigation and restoration when any failure is occurred and an efficient maintenance operation for preventing the failure in advance. <P>SOLUTION: The same controller 5a as that at a user side and a simulation device 23 for simulating a system at the user side are installed at a maker side, and a program in a user side arithmetic processing part 9 and user side operation status data stored in a memory 10 when the failure is occurred are automatically transmitted, and the program is integrated into a maker side arithmetic processing part 9a, and the maker side operation status data obtained by operating the simulation device 23 and the user side operation status data are compared by a maintenance support device 25, so that it is possible to quickly specify the factor of the failure. Also, the user side operation status data are regularly compared with the maker side operation status data or the past user side operation status data stored in a maintenance data server 31, so that it is possible to specify a differential changed section, and the inspection of the corresponding components is selectively executed, so that it is possible to achieve efficient maintenance check. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a maintenance support device, a maintenance support method, a maintenance support system, a control device, and a control method.

  Conventionally, when a failure occurs in a control device, a maintenance staff connects a maintenance tool to the control device to retrieve operation state data, and diagnoses the control device based on experience. However, since accurate diagnosis cannot be made if it depends on the experience of maintenance personnel, it takes a long time to take measures when a malfunction occurs, resulting in an increase in loss due to non-operation.

  For this reason, there has been considered an apparatus that takes in operating state data via a network and performs a diagnosis, and such an apparatus is described in, for example, Japanese Patent Application Laid-Open No. 2002-23845. In the technology described in this publication, a simulation is performed using a dynamic characteristic physical equation of equipment, and diagnosis is performed by comparing the simulation result with operating state data transmitted via a network.

Japanese Patent Laid-Open No. 2002-23845

  However, although the simulation based on the dynamic characteristic physical equation of the device can roughly simulate the operation of the control device, for example, the control function customized for each control device or set for each control device An abnormality caused by a control constant or the like could not be determined, and a highly accurate diagnosis for each control device could not be performed.

  An object of the present invention is to provide a maintenance support device, a maintenance support method, a maintenance support system, a control device, or a control method that enables highly accurate diagnosis suitable for the control function of each control device.

  In order to achieve the above object, the present invention receives and stores an operation program and customer operation state data of a customer device via a communication line, and simulates operation state data obtained by operating the operation program with a simulation device. The stored customer operating state data and the simulated operating state data are read and compared to diagnose the customer device.

  ADVANTAGE OF THE INVENTION According to this invention, the highly accurate diagnosis according to the control function of each control apparatus is attained.

  The best mode for carrying out the invention will be described below with reference to the drawings.

First, the configuration of the motor control device 5 to be monitored will be described. In FIG. 2, an electric motor control device 5 includes an AC power source 1, an AC power source 2 that converts AC power of the AC power source 1 into desired power, an electric motor 3 that is driven by electric power output by the power conversion device 2, and an electric motor 3. It comprises a control device 5 that controls the output torque and speed of the motor 3 so that the driven device (load device) 4 and the load device 4 satisfy desired characteristics. The speed detector 6 directly connected to the motor 3 detects the speed of the motor. The current detector 7 detects and outputs the output current of the power converter 2. A voltage detector 8 detects the output voltage of the power converter 2. Output signals from the speed detector 6, current detector 7, and voltage detector 8 are input to the arithmetic processing unit 9 in which the control logic in the control device 5 is programmed, and various arithmetic processes are performed in the arithmetic processing unit 9. Then, a signal for controlling the power converter 2 is output. Here, the control program is a combination of commands so that the electric motor control device 5 is operated to obtain a predetermined result. Further, in the control device 5, control state information (for example, output current, output voltage, output frequency, etc.) and failure information (for example, overvoltage, The overcurrent etc.) is stored in the memory 10. The control state information and the failure information are referred to as operation state data. In addition, the maintenance tool 12 can be connected to the external output terminal 11 of the motor control device 5 and can be taken out from the memory 10 storing the operation state data in the arithmetic processing unit 9.

  A control program for controlling the motor control device 5 will be described with reference to FIG. The signal name A, signal name B, signal name C, and signal name D input to the control program are, for example, a speed signal detected by the speed detector 6, a current signal detected by the current detector 7, and a voltage detector. 8 is a voltage signal or the like detected at 8. The signal name G and the signal name R output from the control program are, for example, a voltage command and a frequency command.

  Here, when focusing on the A1 block, the signal name A and the signal name B are input to the A1 block. The A1 block performs the calculation along the predetermined arithmetic expression and the A1A gain value used in the arithmetic expression based on the signal name K from the B4 block together with the input, and is limited not to be larger than the A1A limiter value. Is added to output the signal name C. Similarly, in the A2 block, calculation is performed according to the A2B gain value and the A2B limiter value. Hereinafter, signal processing is also performed in the A3 block and A4 block according to the program diagram of FIG. 3, and finally the signal name G and the signal name R are output. In this specification, a program including a gain value and a limiter value is referred to as a control program.

FIG. 1 is an overall system diagram. A plurality of control devices are provided as the control devices 5,. The operation state data stored in the memory 10 in the control device 5 and the program in the arithmetic processing unit 9 are converted into serial transmission information (serial data) by the converter 13, and the output of the converter 13 is the user side local network. 15 is input to the converter 14 which converts the information to 15. Connected to the user-side local network 15 are a user-side terminal device 16 that displays information in the network 15 and a converter 17 that exchanges information between the user-side local network 15 and the Internet line (network) 18. The control devices 5,... 5n are configured as a customer facility A43-1. Further, a customer facility B43-2 configured in the same manner is connected to the Internet line 18 via the converter 45. The Internet line 18 is connected to the manufacturer-side local network 20 via a converter 19 that exchanges information between the Internet line 18 and the manufacturer-side local network 20. These control devices 5,..., 5 n are installed at a so-called site, but a user-side terminal device 16 is installed in a control room separated from them. For example, when the control device 5 enters an abnormal state such as an overcurrent, the information is transmitted to the user terminal device 16 via the converter 13 and the user local network 15. When the information specifying the information and the abnormal control device (5,... 5n) is displayed on the display of the user terminal device 16, the administrator moves from the control room to the site, and the corresponding control device 5 ... 5n are inspected. 5a is the same as the user-side control device installed on the manufacturer side, and the calculation in the user-side control device 5 out of the information in the manufacturer-side local network 20 via the converter 21 and the converter 22 is performed. The program information in the processing unit 9 is converted for the control device and stored in the arithmetic processing unit 9a in the manufacturer-side control device 5a. The manufacturer-side control device 5a is a model that stores a user-side system (AC power source 1, power conversion device 2, motor 3, load device 4, speed detector 6, current detector 7, voltage detector 8) as a model. A device 23 is connected via an interface device 24. The operating state data obtained by driving the simulation device 23 by the manufacturer-side control device 5a is stored in the memory 10a, converted into serial transmission information (serial data) by the converter 22, and the output of the converter 22 is the manufacturer's side. The data is input to a converter 21 that converts information to the local network 20. In addition, the manufacturer-side local network 20 includes a manufacturer-side maintenance support device 25 that displays, compares, processes, and selects restoration procedures in the network 20, operation status data at the time of occurrence of failures in the past, and various failures. And a maintenance support data server 27 for storing access information for exchanging maintenance support information on the Internet homepage. Here, the failure data server 26 accesses a failure operation state database as shown in FIG. Also connected to the Internet line 18 is an automatic bank transaction system 29 that receives the type of processing and usage from the maintenance support data server 27 via the converter 28 and automatically collects the user's usage fee according to the contents. ing. The maintenance support data server 27 accesses a maintenance support database as shown in FIG.

Next, the data flow will be described with reference to FIG. First, in step 401, in the electric motor control device 5 on the user side, for example, if the current value detected by the current detector 7 exceeds a predetermined value and is determined to be an overcurrent, it is assumed that a malfunction has occurred in the electric motor control device 5. The user side operation state data stored in the memory 10 of the arithmetic control unit (arithmetic processing unit) 9 is automatically transmitted to the user side local network. At the same time, the user side operation state data and the program in the arithmetic processing unit 9 (the program shown in FIG. 3) are automatically transmitted to the manufacturer side local network.

  In response to this, in step 501, the contents of the defect are automatically displayed on the screen of the user terminal device 16 as shown in FIG. As shown in FIG. 6, on the screen of the user side terminal device 16, the equipment name, the date and time of occurrence of the failure, the operation state at the time of the failure, the operation state data file name, and the control device program name are displayed.

  In step 103, the manufacturer's maintenance support device 25 automatically displays the defect content as shown in FIG. As shown in FIG. 7, on the screen of the manufacturer side maintenance support device 25, the customer name, equipment name, failure occurrence date and time, operation state at the time of failure, operation state data file name, control device program name, failure factor 1 and failure Factor 2 is displayed.

  On the other hand, in step 101, the program of the motor control device 5 transmitted for comparison in the simulation device 23 + maker-side control device 5a is automatically incorporated into the manufacturer-side control device 5a. At the same time, system parameters on the user side are automatically extracted from the program and incorporated in the simulation device 23 that simulates the system on the user side. In step 102, the simulation device 23 is driven to obtain manufacturer side operation state data. In step 104, the cause at the time of occurrence of the malfunction is specified.

  That is, the details of specifying the cause of the failure will be described with reference to the flowchart shown in FIG.

  In step 601, the user side operation state data is compared with the manufacturer side operation state data.

A comparison for determining the coincidence between the manufacturer-side operation state data and the user-side operation state data will be described with reference to FIG. The operating state data input to the manufacturer-side maintenance support device 25 is compared when investigating the cause of failure or during maintenance support before periodic inspection. As a result of extracting and analyzing feature quantities of data displayed on the screen, such as error, maximum / minimum value, maximum / minimum value of change rate, fluctuation component (frequency analysis result), etc. Are identified, and these factors are used comprehensively to determine consistency. Further, as a waveform comparison, the matching degree is confirmed by superimposing on the same axis, and the matching is judged by quantitatively judging using a neural network or fuzzy. By performing such comparative analysis, when the cause of the accident is investigated, the reproducibility of the phenomenon at the time of the accident can be quantitatively grasped, and the cause identification from the tendency of the reproducibility when the condition is changed is supported. In step 602, it is determined whether the phenomenon has been reproduced, that is, matched. If it is determined in step 602 that the phenomenon has been reproduced, it is determined in step 603 that there is a problem with the control program or control constant setting. In step 604, signal trend evaluation in the control program is performed. Regarding the control constant setting, for example, in the case of “overcurrent”, the gain or limit value of the speed control system is changed as shown in the item “abnormal control constant” shown in FIG. Change the gain or limiter value. Further, for example, in the case of “overvoltage”, as shown in the item “control constant abnormality” shown in FIG. 8, the gain and limiter value of the voltage control system are changed, or the gain and limiter value of the current control system are changed. change. In step 106, the cause of the malfunction is identified based on such a result.

  In the above diagnosis, if the control constant is abnormal, the fact that the control constant should be set to a normal numerical value may be transmitted to the user side terminal device 16, and the manufacturer side maintenance support device 25 may set an appropriate value. May be calculated to display this value. Further, the manufacturer-side maintenance support device 25 may rewrite the program with the appropriate control constant and transmit the rewritten program to the user-side terminal device 16. For example, the program is transmitted after being rewritten with the correction value shown in FIG. In this case, the program in which the control constant is rewritten is stored in the control device 5.

  In the investigation of the cause of a failure, if the operating conditions such as speed and load are not the same, and if it does not reproduce, the voltage drop, signal line, etc. in the power supply, sensor, load side, converter, etc. If the user's operating state data can be reproduced, the simulated factor is identified as the cause of failure and the recovery method for the cause is determined. . On the other hand, if the operating conditions such as speed and load are reproduced in the same state, the cause is considered to be the control program. In this case, it is necessary to specify whether the control constant is bad or the program is buggy. There is. Normally, since the control program performs closed-loop control, it is difficult to specify which part has started and the failure has occurred, and specifying from the operating state data at the time of the failure is limited in the number of data. Therefore, it is often more difficult. On the other hand, in the present invention, the phenomenon can be reproduced by the manufacturer's system and there is no restriction on the number of data (signal type and number of data points) at that time.

  FIG. 25 is an embodiment that supports the identification of a defective portion of the control program in step 604. The configuration of the control program is visually displayed in the form of a block diagram, and the signal names and data values at each location are displayed. And each part changes with the thickness and color of a line according to the set value (a magnitude | size and a change rate). In addition, a time-series data waveform can be confirmed by designating each signal name. By visually displaying in this way, it is possible to identify where a specific change has occurred first, and control constants (design values such as gain, limiter, change rate limit value, etc.) related to the specific location. The cause of the problem can be identified from the consistency and consistency of the program (four arithmetic operations, signal polarity, etc.), and recovery means (change of control constant or program correction) for the cause can be determined.

  The identification of the cause of the failure when the phenomenon is not reproduced in step 602 will be described. In step 605, it is determined that there is a factor other than the control.

  That is, in order to identify the cause of the failure, the operation state data close to the failure cause is called from the failure operation state database stored in the failure data server 26 from the failure information of the operation state data, and the comparison is repeatedly performed. . First, in step 606, the past operating state data in the data server is searched for failure factors or the like. As shown in FIG. 10, in the malfunction operation state database stored in the defect data server 26, in addition to the customer name, the equipment name, the defect occurrence date and time, the operation condition data file name and control corresponding to the failure factor 1 are stored. The device program name is specified, and the cause of failure, recovery procedure, and designer comments are stored. Furthermore, in the malfunction operation state database stored in the malfunction data server 26, as shown in FIG. 11, user-side operation condition data is stored for typical failure factors such as overcurrent and overvoltage. It is remembered. In FIG. 11, when the failure factor is an overcurrent, the user side operation state data when the load is excessive, the user side operation state data when the motor is abnormal, and the user side operation state data when the control constant is abnormal are stored. ing. In addition, when the failure factor is an overvoltage, user-side operation state data in the case of sudden load change, user-side operation state data in the case of power supply abnormality, ... user-side operation state data in the case of control constant abnormality are stored. Further, although not shown, other failure factors are also stored.

In step 607, the data stored in the failure data server is compared with the operation state data. That is, in the manufacturer-side maintenance support device 25, in accordance with the failure factor transmitted from the user-side terminal device 16 (for example, overcurrent), the user-side operation state data in the case of an overload, the case of a motor abnormality User-side operation state data: User-side operation state data in the case of a control constant abnormality is sequentially read and compared with user-side operation state data transmitted from the user-side terminal device 16. If the phenomenon does not match in step 608, the process returns to step 606 again.

  If the phenomenon matches in step 608, verification is performed in step 609 to compare the simulation device (manufacturer side operation state data) with the user side operation state.

  If the cause of the failure is identified in step 608, the manufacturer-side operation support data obtained by the simulation device + the manufacturer-side control device 23 is automatically captured in the manufacturer-side maintenance support device 25 in order to confirm that the failure is correct. Then, the cause of the problem is verified by comparing it with the user-side operation state data automatically transmitted from the user side. As described above, when the phenomenon is reproduced in step 610, the cause of the failure is specified in step 106.

  An operation for newly identifying when a defect is not identified at step 104 or when a phenomenon cannot be reproduced at step 610 and the cause of the defect is not verified will be described. The manufacturer-side maintenance support device 25 searches the failure database according to the failure factor (for example, overcurrent) transmitted from the user-side terminal device 16. As shown in FIG. 8, the defect database stores items in order of items to be checked. In the case of an overcurrent, check items are configured in the priority order of overload, motor abnormality, converter abnormality, sensor abnormality, and control constant abnormality.

  In the case of an overcurrent, first check whether the cause was an overload. That is, in order to check whether or not an abnormal load is applied by the customer operation data, the load is changed to an abnormal state value by the customer operation data, and the simulation apparatus is driven to obtain the manufacturer side operation state data. If the manufacturer-side operation state data matches the user-side operation state data, it can be determined that the cause is an overload.

  If they do not match, it is checked whether the motor is the next priority for comparison. In order to check whether there is an abnormality in the electric motor or the wiring, the movement of the electric motor is changed to an abnormal state value, or the wiring is changed to a disconnected state. Then, as in the case of the previous determination of overload, the simulation device is driven to obtain manufacturer side operation state data. If the manufacturer-side operation state data matches the user-side operation state data, it can be identified that the cause is a motor abnormality. If the phenomenon is not reproduced in step 610, that is, if they do not match, the process returns to step 609 to check the next item in the comparison priority order. In case of overvoltage, check in order of sudden load change, power supply abnormality, converter abnormality, sensor abnormality, control constant abnormality.

  The determination of coincidence is as described above. In step 106, the cause of the malfunction is specified based on the determination in step 104. The identified failure cause is transmitted to the failure data server 26.

  In step 203, the recovery procedure corresponding to the cause of the failure is transmitted from the failure data server 26.

  In step 107, the manufacturer's maintenance support device 25 displays a recovery procedure. Further, the recovery procedure obtained in step 108 is transmitted to the maintenance support data server 27 together with the processing content and the specified cause of the failure.

  In step 301, the maintenance support data server 27 registers the recovery procedure corresponding to the identified cause of the failure together with the current processing content on the Internet homepage. Here, when it is necessary to modify and modify the program in the arithmetic processing unit due to the cause of the malfunction, the modification program is registered on the same Internet homepage after driving the simulator with the modification program and confirming normal operation.

  In step 502, the user side terminal device 16 transmits the user ID and password notified separately by e-mail or the like to the maintenance support data server 27 to request access.

  In step 301, the maintenance support data server 27 transmits a cause of failure, a recovery procedure, and a correction program, which are processing contents corresponding to the request, in response to the access request.

  In step 503, the user terminal device 16 displays a screen for accessing the maintenance support Internet homepage. As shown in FIG. 12, the maintenance support system screen display shows the current processing content, cause of failure, recovery procedure, and recovery data such as correction program. Download, recovery data circulation, printing, and saving according to the instructions on the screen I do. Then, the maintenance staff on the user side performs the recovery work according to the guidance of the displayed or downloaded recovery data.

  In step 109, the maintenance support device (manufacturer side) 25 transmits a user usage status request. On the other hand, in step 302, the maintenance support data server 27 registers the user usage status and transmits information indicating the registration. When the user usage status is registered, an automatic bank transaction is applied to the automatic bank transaction processing system 41 in step 303. That is, information on the usage status is transmitted.

  In response to this application, in step 601, the bank automatic transaction processing system 41 accesses the maintenance support Internet homepage access information from the maintenance support database as shown in FIG. 13 stored in the maintenance support data server (manufacturer) 27. (User ID, password, number of accesses), usage status such as processing contents are reported, and depending on usage status (for example, free of charge in case of trouble due to manufacturer side, charged in case of normal maintenance processing) The usage fee is automatically deducted. Note that the user-side operating state data collected this time is transmitted to the defect data server together with the current processing content in step 202 and stored in the database for use at the next occurrence of the defect.

  By using such a maintenance support method, it is possible to promptly communicate and transmit the failure status, operation status data, and program when a failure occurs, and also simulate the same control device and user side system as the user side including the program. By comparing and examining the operation status data using the device and the operation status data at the time of failure, the cause investigation time can be shortened and the accuracy can be improved, and the system downtime can be shortened to reduce the loss on the user side when the system is not operating. it can.

  FIG. 15 shows another embodiment of the device of the present invention. The parts having the same reference numerals are the same as those in the above-described embodiment, and the description thereof is omitted. In particular, this point will be mainly described because it requires a user side permission during automatic data transmission. In general, the operation data on the user side is a trade secret, and it is not preferable that the operation state data or the like be transmitted outside without permission. In addition, there are cases where the influence at the time of failure is slight, or the cause can be easily identified and recovered by the user, and it is not preferable to transmit data in all cases. Therefore, in FIG. 15, a data holding device 30 having a function of blocking data transmission is installed while connecting from the user side local net to the Internet line. Also, as shown in FIG. 16, in step 504, a message requesting whether data transmission is possible is displayed on the screen of the user terminal device 16. In step 505, when information indicating that data transmission is permitted is given to the user terminal device 16, the information is transmitted from the user terminal device 16. Also, in order to assist the maintenance staff or administrator on the user side to determine whether data transmission is possible or not, as shown in FIG. The recovery procedure corresponding to the failure information was displayed. Also, if necessary, the contents of this process are circulated, printed, and saved to related departments and parties in the form of reports.

  By using such a maintenance support method, it is possible to quickly maintain the security on the user's data and contact, store, and print related departments and parties related to the failure status, and the cause of the failure can be identified by the user. In a difficult case, the same processing as in the first embodiment is promptly performed, and the loss on the user side that occurs during the system stop period can be reduced.

  FIG. 18 shows another embodiment of the apparatus according to the present invention, which relates to a normal maintenance support system. The first and second embodiments are the maintenance support apparatus 25 on the manufacturer side. The difference is that the server referred to when comparing the operation state data is the maintenance data server 31.

The data flow in the present invention will be described with reference to FIG. First, in step 506, the user side terminal device 16 automatically performs a display for inviting collection of maintenance support data as shown in the screen of FIG. 21 before a predetermined period from the periodic inspection date. In step 507, when the user side terminal device 16 is permitted to collect maintenance support data, a signal instructing the motor control device 5 to collect user side operation state data is transmitted.

  In step 402, the motor control device 5 collects user-side operation state data under the set conditions. Then, when information indicating that data transmission is permitted in steps 504 and 505 as described in the second embodiment is given to the user side terminal device 16, the user side operation state data and the calculation processing unit are transmitted via the Internet line. Are automatically transmitted to the manufacturer's local network.

  The maintenance content is automatically displayed on the manufacturer side maintenance support device 25 as shown in FIG. Next, the person in charge on the manufacturer side automatically incorporates the user-side control device program transmitted for comparison and consideration into the manufacturer-side control device, and automatically extracts the user-side system parameters from the program according to the maintenance details. Then, a manufacturer's operating state data is obtained by driving a simulation device that simulates the developed user's system.

  The obtained manufacturer-side operation state data is automatically taken into the manufacturer-side maintenance support device 25 and is compared with the user-side operation state data automatically transmitted from the user side. Identify the site of change. Here, in order to investigate the factor that causes the unique change, it is compared with the operation state data obtained by changing the conditions of the simulator.

  Details of specifying the singular change part at the time of maintenance support, which is step 105, will be described with reference to the flowchart shown in FIG. First, in step 621, the user side operation state data and the manufacturer side operation state data are compared. In step 622, based on the comparison in step 621, it is determined whether or not there is a unique change site. If there is no peculiar change part at step 622, it is judged at step 623 that there is no peculiar change, and a normal inspection inspection procedure is displayed.

  If there is a peculiar change part in step 622, it is determined in step 624 that there is a factor causing the change. The past operation state in the maintenance data server 31 is searched from the maintenance content. In step 626, the storage in the maintenance data server and the operation state data are compared. If the phenomenon does not match in step 627, the process returns to 625 again to perform a search again. If the phenomenon matches in step 627, in step 628, the condition is set and the simulator 23 + manufacturer-side control device 5a is operated to obtain the maker-side operating state data, which is verified by comparing with the user-side operating state data. I do. If the phenomenon is not reproduced in step 629, the process returns to step 628 again to perform resetting. If the phenomenon is reproduced in step 629, a specific change site is specified in step 110. Further, at the time of maintenance support before the regular inspection, the specific part that has changed from the past maintenance data is quantitatively extracted to support the identification of the priority inspection items.

  In the maintenance data server 31, there may be a case where the corresponding past operation state data is called from the maintenance operation state database as shown in FIG. In some cases, the program and control constant settings are not changed, or the programs are compared.

  When a specific change part is specified, the maintenance data server 31 is requested for a priority inspection item and an inspection procedure corresponding to the change part. In step 205, the maintenance data server 31 transmits the priority inspection item and the inspection procedure corresponding to the called change part.

  In step 113, the manufacturer-side maintenance support device 25 transmits the inspection procedure corresponding to the identified priority inspection item to the maintenance support data server 27 together with the current processing content. In step 304, the maintenance support data server 27 registers the transmitted inspection procedure corresponding to the specified priority inspection item together with the current processing content on the Internet homepage of the maintenance support server. The user side terminal device 16 inputs a user ID and a password separately notified by e-mail or the like, and accesses the maintenance support Internet homepage to display a maintenance support system screen as shown in FIG. Maintenance data such as processing contents, priority inspection items, and inspection procedures is displayed, and download, maintenance data circulation, printing, and storage are performed according to instructions on the screen. Then, the user-side maintenance staff conducts periodic inspections according to the guidance of the displayed or downloaded maintenance data. In the automatic banking transaction processing system, as already explained, access information (user ID, password, number of accesses) of the maintenance support Internet homepage from the maintenance support database as shown in FIG. 13 stored in the manufacturer's maintenance support server. Therefore, the usage status of the processing contents and the like is reported, and the usage fee is automatically deducted according to the usage status (for example, it is performed free of charge in the case of trouble processing due to the manufacturer side, and charged in the case of normal maintenance processing). Note that the user-side operating state data collected this time is transmitted to the maintenance data server 31 together with the current processing content in step 202 and stored in the database for use in the next maintenance support.

  By using such a maintenance support method, prior to periodic inspection, it is possible to compare the operation status data of the user side device with the data of the manufacturer side simulation device, or to compare the past operation status data with the priority inspection. By extracting items, preventing problems in advance, and supporting parts maintenance, it is possible to prevent problems before they occur and reduce the loss on the user side that occurs when problems occur.

  Generally, all data in the control device cannot be collected due to the limitation of the memory capacity installed in the control device on the user side. The condition of the collected data is only one set of data at the time of occurrence of the failure. Since the control device generally performs closed-loop control, it is necessary to specify which part of the control system starts from the limited data only from this limited data. There is a possibility that the origin of the malfunction is a malfunction of the power supply, converter component, sensor, and load device of the user side system. Therefore, the cause of the problem is investigated by comparing the operating state data obtained by incorporating the program of the user-side control device at the time of occurrence of the trouble into the manufacturer-side control device and operating the simulation device of the user-side system. That is, although the manufacturer's control device uses the same device as the user side for maintenance support, the memory capacity for data storage can be expanded, and the data stored under the same conditions can be changed because of the simulation device. Is also possible. It is also possible to easily collect operating state data by changing model settings of the power supply, converter parts, sensors, load devices, etc. of the user side system. Therefore, identification of the cause can be supported by increasing the number of data that can be used for the cause investigation. Further, not only the cause of failure but also the maintenance support before the periodic inspection can be similarly supported by increasing the number of data to identify important inspection items. Here, the cause and important inspection items are further easily identified.

  Again, in FIG. 9, the operating state data input to the maintenance support device is compared when investigating the cause of the failure or during maintenance support before the periodic inspection, but the waveform is displayed on the screen. By comparing and comparing the data, and extracting and analyzing the feature values of the data, such as error, maximum / minimum value, maximum / minimum value of change rate, fluctuation component (frequency analysis result), etc. Supports judgment and identification of specific changes. When comparing waveforms, it is possible to check the degree of matching by superimposing them on the same axis, or to make a quantitative determination using a neural network or fuzzy. By performing the comparative analysis as described above for each signal, when investigating the cause of the accident, it is possible to quantitatively grasp the reproducibility of the phenomenon at the time of the accident, and identify the cause from the tendency of the reproducibility when the conditions are changed. Can support. Further, at the time of maintenance support before the periodic inspection, it is possible to support the identification of the priority inspection items by quantitatively extracting the unique parts that have changed from the past maintenance data.

  As described above, in this embodiment, in order to quickly investigate the cause, an apparatus for simulating the user's system is installed on the manufacturer side, and stored in the program and the memory 10 in the arithmetic processing unit 9 at the time of malfunction. The operation status data is automatically transmitted, and the data at the time of failure and the data of the simulation device are compared and verified. In addition, for security of technical information on user-side data, information (defect status, transfer program, transfer data) for obtaining permission from the maintenance personnel or administrator of the device during data transfer and determining permission is described. Report is automatically created and promptly communicated to the judge. In addition, comparison verification with the simulation apparatus is performed regularly, for example, before periodic inspection, and priority inspection items are extracted in advance from comparison with the previous data to prevent problems in advance and support parts maintenance. Further, at the time of comparison and verification of the simulation apparatus data, a signal change in the simulation apparatus is visually displayed, so that a defective part is quickly identified or a part having a characteristic different from the previous data is identified quickly.

  In this way, when a failure occurs, data can be transferred while maintaining the security of the user side data, the cause can be quickly investigated by comparison verification with the manufacturer's simulation device, and the recovery procedure can be communicated to the user side . As a result, the loss on the user side that occurs when the system is not operating can be reduced by shortening the system stop period. Prior to periodic inspections, priority inspection items are extracted by comparing the operation status data of the user-side device with the data of the manufacturer-side simulation device, or by comparing the past operation status data, and preventing problems in advance. , By supporting the maintenance of parts, it is possible to reduce the loss on the user side due to the occurrence of a problem. In other words, the purpose of shortening the system downtime on the user's side when a problem occurs is realized by supporting the investigation of the cause by comparing the automatic transfer of operating state data with the simulation device data on the manufacturer's side.

  In the present embodiment, the motor control device has been described. However, in the system using the control device, if the user side device can be modeled, not only the motor but also a system such as an uninterruptible power supply device, for example. Applicable.

The block diagram of the maintenance assistance system of the motor control apparatus which shows the 1st Embodiment of this invention. The block diagram of the electric motor control apparatus of this invention. 4 is an example of a control program in the first embodiment of the present invention. The data flow figure in the 1st Embodiment of this invention. FIG. 5 is a flowchart for specifying a cause when a problem occurs in the first embodiment of the present invention. The example of a screen display of the user side terminal device at the time of the malfunction occurrence in the 1st Embodiment of this invention. The example of a screen display of the maker side terminal device at the time of the malfunction occurrence in the 1st Embodiment of this invention. The example of a malfunction cause check in the 1st Embodiment of this invention. The example of a comparison screen display of the driving | running state data in the 1st Embodiment of this invention. The example of a malfunction driving | running state database in the malfunction data server in the 1st Embodiment of this invention. The example of malfunction operation state data in the malfunction data server in the 1st Embodiment of this invention. The screen display example of the user side terminal device at the time of the recovery assistance in the 1st Embodiment of this invention. 3 is a maintenance support database example in the maintenance support server according to the first embodiment of the present invention. The figure which shows correction of the control constant of the maintenance assistance server in the 1st Embodiment of this invention. The block diagram of the maintenance assistance system of the motor control apparatus which shows the 2nd Embodiment of this invention. The data flow figure in the 2nd Embodiment of this invention. The example of a screen display of the user side terminal device at the time of the malfunction occurrence in the 2nd Embodiment of this invention. The block diagram of the maintenance assistance system of the motor control apparatus which shows the 3rd Embodiment of this invention. The data flow figure in the 3rd Embodiment of this invention. The flowchart of the specific change site | part specification at the time of maintenance assistance. The example of a screen display of the user side terminal device at the time of the maintenance data collection in the 3rd Embodiment of this invention. The example of a screen display of the maker side terminal device at the time of the maintenance assistance in the 3rd Embodiment of this invention. The maintenance operation state database example in the maintenance data server in the 3rd Embodiment of this invention. The example of a screen display of the user side terminal device at the time of the maintenance assistance in the 3rd Embodiment of this invention. The screen display example of the signal analysis assistance of the user side terminal device at the time of the maintenance assistance in the 1st Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... AC power source, 2 ... Power converter device, 3 ... Electric motor, 4 ... Load device, 5 ... Control device, 6 ... Speed detector, 7 ... Current detector, 8 ... Voltage detector, 9 ... Arithmetic processing part, 10 ... Memory, 11 ... External output terminal, 12 ... Maintenance tool, 15 ... User side local network, 16 ... User side terminal device, 18 ... Internet line, 20 ... Manufacturer side local network,
23 ... User side system simulation device, 24 ... Manufacturer side control device and simulation device interface device, 25 ... Manufacturer side maintenance support device, 26 ... Defect data server, 27 ... Maintenance support data server, 29 ... Bank automatic transaction system, 31: Maintenance data server.

Claims (25)

  A receiving device that receives information from a terminal via a communication line, and a first device that stores information that is included in the control program of the device operation data and diagnosis target device received through the receiving device or the control program. A storage area; a second storage area for storing simulated operation data obtained by operating the simulator on the basis of the control program, information included in the control program or information specifying the control program; and a first storage area A maintenance support device, comprising: an operation unit that compares the device operation data stored in the storage device and the simulated operation data stored in the second storage area to diagnose the diagnosis target device.   The maintenance support apparatus according to claim 1, wherein the control program is for operating the diagnosis target apparatus when the diagnosis target apparatus is in an abnormal state.   2. The control program according to claim 1, wherein at least part of the control program is changed and the changed control program is transmitted based on the diagnosis, or information for changing the control program is transmitted. A maintenance support device.   4. The maintenance support apparatus according to claim 3, wherein the control program has a control constant changed from an initial state.   2. The maintenance support apparatus according to claim 1, wherein the simulated operation data is obtained by changing a control factor of a control program for operating the simulation apparatus and operating the control program.   In Claim 5, it has the 3rd storage area which memorizes a plurality of control factors, acquires simulation operation data for every a plurality of control factors, and whenever it acquires simulation operation data, the acquired simulation operation data And a maintenance support apparatus, wherein the operation data for diagnosis is compared.   The maintenance support apparatus according to claim 6, wherein the third storage area is configured to store a plurality of control factors for each of a plurality of failure factors.   8. The maintenance support apparatus according to claim 7, wherein the failure factor is transmitted from a customer terminal.   The maintenance support apparatus according to claim 1, wherein the maintenance support apparatus is configured to identify an inspection item and perform diagnosis for the inspection item.   The maintenance support apparatus according to claim 1, wherein the diagnosis is performed in consideration of past diagnosis information.   A receiving device that receives information from a customer terminal via a communication line; and a first storage area that stores a customer device control program and customer operating data received via the receiving device; The control program is diagnosed based on the function, and the function of the program is displayed as a block diagram on a display screen, and a part of the block diagram is displayed so that the abnormal part can be visually identified. A maintenance support device.   A transmission unit that transmits the control program and operation state data of the apparatus to the maintenance support apparatus via a communication line; and a reception unit that receives diagnosis information diagnosed based on the control program and the operation state data. The maintenance support device characterized by this.   13. The information for requesting permission for transmission of the control program and operation state data is displayed on a display device according to claim 12, and transmission of the control program and operation state data is permitted when a signal indicating permission is input. A maintenance support device characterized by that.   A transmission / reception device that transmits and receives information via a communication line, and a control program and operation state data of the device are transmitted to the diagnosis device via the communication line, and are included in the operation state data and the control program and control program. A maintenance support apparatus, comprising: a calculation unit that receives from the diagnosis apparatus diagnosis information diagnosed based on information included or information included in information specifying a control program.   A receiving device that receives information from a terminal via a communication line, a first storage area that stores device operating data received via the receiving device, and a specific change site as an inspection item from the stored device operating data A maintenance support device comprising means for specifying   The maintenance support apparatus according to claim 15, wherein the specifying is performed based on past operation data.   17. The maintenance support apparatus according to claim 16, wherein data obtained by operating a simulation apparatus is obtained based on data relating to driving, and the identification is confirmed based on the data.   In the control device that controls the device by operating the control program, the control program and the operation state data of the device are transmitted to the diagnosis device via the communication line, and the diagnosis is made based on the control program and the operation state data. A control device receiving diagnostic information.   The information received from the terminal via the communication line is received by the receiving device, the control program for the diagnosis target device received via the receiving device, the information included in the control program or the information specifying the control program, and the device operating state data The apparatus operation data stored in the first storage area is stored in the second storage area, and is stored in the first storage area. And a maintenance support method for diagnosing the diagnosis target device by reading out and comparing the simulated operation data stored in the second storage area.   In a control method for controlling a device by operating a control program, a control program for the device, information included in the control program, information for specifying the control program, and device operating state data are transmitted to the diagnostic device via a communication line. And receiving diagnostic information diagnosed based on information of the control program and operating state data.   The terminal transmits the device operation data and the control program of the diagnosis target device, the diagnosis device operates the simulation device based on the control program, and compares the device operation data with the simulation operation data obtained by the operation. The maintenance support system is characterized in that the diagnosis is performed and the diagnosis information is transmitted to the terminal.   22. The maintenance support system according to claim 21, wherein a specific change site is specified by comparing the two data, and a priority inspection item and an inspection procedure corresponding to the specific change site are output.   In Claim 21, the specified cause of failure is transmitted to the failure data server, and the failure data server outputs a recovery procedure corresponding to the cause of the failure. Transmitted to the maintenance support server, the maintenance support server is registered so that the recovery data can be accessed via a communication line, the usage status of the maintenance support server is registered, and charging is performed based on the usage status. A featured maintenance support system.   The failure information included in the device operation state data is transmitted to the failure data server, and past operation state data corresponding to the failure information stored in the failure data server is obtained together with the device operation state data. A maintenance support system characterized in that the cause of the malfunction is specified by comparing the two data, and the apparatus operating state data collected this time is stored in the malfunction data server. In claim 21, when transmitting the device operating state data and the control program at the time of malfunction via the communication line, a screen for requesting permission of data transmission from the maintenance staff or the administrator is displayed on the screen of the terminal device, Display the recovery procedure corresponding to the failure status and the cause of the failure, determine whether data transmission is possible, circulate, print or save the processing contents, and circulate and print the recovery data when the recovery data is obtained Alternatively, a maintenance support system characterized by being configured to be storable.

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