JP2007140997A - Apparatus for diagnosing fault - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fault diagnostic apparatus capable of reducing preparation and operating a system in an early stage. <P>SOLUTION: When the fault occurs, a fault diagnostic processing part 22 retrieves an action result DB 27, based on an alarm signal for specifying the kind of the inputted fault and a state signal for indicating the state of each part of equipment to be specified by the alarm signal, and specifies the action against the main cause of the fault. When applicable action result data is not registered in the action result DB 27, the fault diagnosis processing part 22 generates the action result data, including the main cause inputted by a user; the alarm signal for the action and the occurrence of fault; and a state signal value, and registers the data in the action result DB 27. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a failure diagnosis apparatus, and more particularly to presentation of a cause of a failure occurring in a production facility and a measure for the failure.

  FIG. 9 is an overall configuration diagram of the failure diagnosis monitoring system. This system includes a subsystem on the monitoring center 1 side for remotely monitoring production facilities, and a subsystem in a factory 10 where the production facilities to be monitored are installed. A subsystem in the factory 10 or the like includes a PLC (Programmable Logic Controller) 14 to which one or more production facilities 12 such as a production robot and an inverter are connected, and a LAN (Local Area Network) or sequencer network (hereinafter referred to as “ And a fault diagnosis device 20 to which one or a plurality of PLCs 14 are connected via a LAN 16. On the other hand, the subsystem on the monitoring center 1 side includes a failure diagnosis device 20 installed at a customer and the monitoring device 2 connected to the public network 3 or the public network 3 via the intranet in the monitoring center 1.

  Here, an outline of failure diagnosis and monitoring implemented in this system configuration will be described. When an abnormality such as a failure occurs in any of the production facilities 12 of the factory 10 or the like, the PLC 14 detects the occurrence of the abnormality from the notification from the production facility 12 or from the status signal of the production facility 12 by the abnormality monitoring program of the PLC 14. Then, an alarm signal is output. The failure diagnosis device 20 notifies the monitoring center 1 of the occurrence of an abnormality when an alarm signal is sent from the PLC 14. When the monitoring device 2 of the monitoring center 1 receives an abnormality notification issued from the production facility 12 or detected from the production facility 12, the maintenance staff is contacted. The maintenance engineer goes to the site where the abnormality has occurred according to the notification, identifies the cause of the abnormality, takes measures for repairing, etc., and puts the production facility 12 into an operable state.

  FIG. 10 is a block diagram of a conventional failure diagnosis apparatus 20. The conventional failure diagnosis apparatus 20 includes a signal input unit 21, a failure diagnosis processing unit 201, a display unit 24, a failure occurrence notification processing unit 25, and a diagnosis support information DB 202. When a failure occurs in any of the production facilities 12, the PLC 14 sends an alarm signal that can specify the type of abnormality and a signal sent from the connected production facility 12 at the time of the failure to the failure diagnosis device 20. The signal input unit 21 inputs these alarm signals and the status signal of the production facility 12. The failure diagnosis processing unit 201 identifies the cause of the failure by collating the input data with various data registered in the diagnosis support information DB 202, and acquires a failure repair procedure. The display unit 24 displays the cause and treatment of the failure obtained by the failure diagnosis processing unit 201 on the screen. The failure occurrence notification processing unit 25 notifies the monitoring center 1 that a failure has occurred.

  FIG. 11 is a diagram illustrating a data configuration registered in the diagnosis support information DB 202. As shown in FIG. 11, one or a plurality of failure patterns are associated with the alarm signal, and each failure pattern has data in which factors and measures are described in detail (hereinafter, “factor / treatment detailed data”). ) Are associated. The alarm signal is a data signal that can specify in which production facility 12 the failure has occurred together with the notification of the occurrence of the failure. The production facility 12 outputs signals indicating the state of the facility, such as digital data indicating the presence or absence of contact of a certain part and analog data indicating temperature and humidity, for example. These signals are input via the PLC 14 as described above. From the unit 21 to the failure diagnosis apparatus 20. These signals, also called “devices”, are identified by identification symbols such as “X0” and “Y22”, respectively. In the following description, a signal indicating the state of each part of the production facility 12 with respect to the alarm signal is referred to as a “state signal”. The number of state signals input by the signal input unit 21 varies depending on the number and model of the production equipment 12 connected to the PLC 14, but the value of each state signal (IO state) selected from these state signals. The cause of the failure can be specified by the combination. That is, each failure pattern is determined by a combination of the type of state signal that can specify a failure and the value of the state signal. The factor / action detailed data is data in which the cause of the failure found by specifying the failure pattern and the action for repair are described. Conventionally, all the factor / treatment detailed data are associated with the failure pattern and registered in advance. The reason why the diagnosis support information DB 202 has a hierarchical data structure as shown in FIG. 11 is that a plurality of types of failures may occur in a certain production facility. This is because there are several types of factors.

  As described above, the maintenance staff in charge goes to the site where the abnormality occurs and repairs the production facility 12 so that the production facility 12 can be operated. The information for identifying the content of the repair work, that is, the cause and action of the failure is diagnosed. The failure diagnosis device 20 is selected by referring to the DB 202. The failure diagnosis process for specifying the cause and the measure of the failure in the conventional failure diagnosis apparatus 20 will be described below.

  The signal input unit 21 inputs an alarm signal and a status signal sent from the PLC 14. When the failure diagnosis processing unit 201 detects that a failure has occurred in any of the production facilities 12 due to the input of an alarm signal, each value of the status signal received from the signal input unit 21 and the diagnosis support information DB 202 Compare and collate with each failure pattern registered in the failure pattern table. Then, by specifying the matching failure pattern, the corresponding factor / treatment detailed data is extracted from the factor / treatment table. For example, according to the example shown in FIG. 11, the signals “X0 = ON” and “X5 = OFF” among several tens to several hundreds of signals input when a failure occurs (alarm signal 1 is input). If "Y22 = ON", the cause of the failure is determined to be "hanger shape ...", and the repairing action can be specified as "hanger shape ...". The display unit 24 displays the factor / treatment detailed data specified by the failure diagnosis processing unit 22 on the screen.

  The worker in charge who has rushed to the site where the abnormality has occurred grasps the production facility 12 to be repaired and the content of the work by referring to the cause of the failure displayed on the screen and the action for repairing the failure, and performs the repair work.

  The conventional failure diagnosis apparatus 20 diagnoses a failure by comparing and collating the data input at the time of failure occurrence with various data registered in the diagnosis support information DB 202 as described above, and causes and repairs of the failure. A treatment for can be presented.

  As described above, in order to be able to present the cause of failure and measures for repair in the past, factor / action detailed data is registered in the database in advance corresponding to each failure pattern and each failure pattern. However, there is a problem that the load of the registration process to be performed in advance is excessive and the system operation cannot be started unless the registration is completed.

  Furthermore, a combination of state signals for identifying a failure (generation of a failure pattern) such as what kind of state signal combination corresponds to which failure, and what action is taken to repair the failure. In addition, in order to register the cause of the failure and the presentation of the treatment (generation of the detailed data of the cause / treatment) in the database, it is impossible to have expertise and know-how for failure diagnosis. In addition, even an experienced professional engineer can identify all failure signal sets (failure patterns) before starting the system operation, identify the failure factors from the failure patterns, and further determine each failure cause. Presenting treatment accurately is an extremely difficult and complicated task.

  An object of the present invention is to provide a fault diagnosis and monitoring apparatus that solves at least one of the above problems.

  In order to achieve the above-described object, a failure diagnosis monitoring apparatus according to the present invention is a failure diagnosis apparatus that identifies a cause of a failure that has occurred in one or more facilities and presents a measure for the failure. , A signal input means for inputting a warning signal that can identify the type of failure and a status signal that indicates the status of each part of each equipment that is issued from all equipment, and a status signal that can be issued by each equipment is grouped for each equipment. Means for storing state signal group tables to be held, means for storing failure group tables for grouping and holding the types of failures that may occur in each facility, alarm signal values, and identification of failure factors A procedure for storing treatment result data formed by combining a type and a signal value of a state signal necessary for the operation and description data indicating a cause of the failure and a treatment for the failure The result data storage means, the status signal relating to the facility in which the fault occurred, extracted from the status signal input by the signal input means with reference to the respective tables at the time when the fault occurred, and the signal input means input By comparing and collating each value with the status signal included in each action result data of the same alarm signal as the alarm signal, the cause and action of the failure that occurred are identified, and as a result of the comparison and collation process, the failure Factors that determine the status signal and its signal value necessary for identifying the cause of failure according to the user input operation, and descriptive data indicating the cause of failure and treatment for the failure -Treatment presentation processing means and user input and input from the signal input means when the cause / treatment presentation processing means cannot identify the cause and treatment of the failure Treatment result data registration processing means for newly generating treatment result data based on the data and registering it in the treatment result data storage means, and storing the treatment result data every time a new failure occurs It is.

  In addition, when the cause / treatment presentation processing means cannot identify the cause and action of the failure, the user receives a status signal necessary for specifying the cause of the failure and description data indicating the failure cause and the action for the failure. It has a factor / treatment input processing section that allows the input to be specified.

  Alternatively, the factor / treatment presentation processing means compares with the state signal extracted from the inputted state signal according to the search condition designated by the user when the cause and treatment of the failure cannot be specified. A search processing unit for determining the cause and treatment of a failure that occurred while changing the range of treatment result data to be collated is provided.

  According to the present invention, the information regarding the cause and treatment of the failure is sequentially registered while operating the system, and the accuracy is improved, so that the amount of data to be registered in advance can be reduced. Thereby, it is possible to reduce the work load required for the registration process in the preliminary preparation stage. Further, the system operation can be started without inputting information on the cause / action of the failure.

  Moreover, the content of the data to be registered in advance may be such as to input the content described in, for example, specifications. That is, even those who do not have specialized knowledge or know-how can perform data registration processing.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

Embodiment 1 FIG.
FIG. 1 is a block configuration diagram of a failure diagnosis apparatus 20 in the present embodiment. The overall configuration of the fault diagnosis and monitoring system in the present embodiment may be the same as the system configuration shown in FIG. Therefore, the description of the system configuration is omitted. In the present embodiment, the configuration of the failure diagnosis device 20 included in the failure diagnosis monitoring system is different from the conventional one. In FIG. 1, the same components as those in the conventional example are denoted by the same reference numerals.

  The failure diagnosis apparatus 20 according to the present embodiment includes a signal input unit 21, a failure diagnosis processing unit 22, a factor / treatment input processing unit 23, a display unit 24, a failure occurrence notification processing unit 25, and a diagnosis support information DB 26. . The signal input unit 21 inputs an alarm signal and a status signal sent from the PLC 14. The failure diagnosis processing unit 22 determines the cause of the failure and a measure for the failure based on the alarm signal and the status signal input by the signal input unit 21 and various data registered in the DBs 26 and 27. When the failure diagnosis processing unit 22 cannot determine the cause of the failure and the action for the failure, the factor / treatment input processing unit 23 performs the status signal necessary for identifying the cause of the failure, the cause of the failure, and the action for the failure. To specify input. The display unit 24 displays the cause and treatment of the failure obtained by the failure diagnosis processing unit 22 on a screen. The failure occurrence notification processing unit 25 notifies the monitoring center 1 that a failure has occurred. The diagnosis support information DB 26 will be described later. The treatment result DB 27 is generated at the time of system operation, and the result data is accumulated.

  The failure diagnosis apparatus 20 in the present embodiment can be realized by a general-purpose computer such as a personal computer (PC) that can be connected to a LAN. Each of the components 21 to 25 included in the failure diagnosis apparatus 20 is realized by a cooperative operation of a software program that exhibits processing functions of each component and hardware resources of the computer. In the present embodiment, it is assumed that each DB 26, 27 is formed in a hard disk drive device built in a computer, but it is not necessarily formed in a built-in type, for example, another computer accessible via a LAN. It may be configured to be held and managed.

  FIG. 2 is a diagram showing a data configuration example of the diagnosis support information DB 26 in the present embodiment. In the diagnosis support information DB 26, each data is registered by being roughly divided into an IO group table in which an IO group is set and an alarm signal table in which an alarm signal type is set. FIG. 3 is a diagram illustrating an example of the data configuration of the IO group, representing the IO group 1 as a representative. The IO group is a data group formed for each production facility and grouping state signals emitted from the production facility. In the present embodiment, as shown in FIG. 3, it is stored and managed as a table. Then, the status signal type and the name of each signal are combined and classified and set for each digital / analog IO. In the case of the same production facility, the same status signal value should be sent when a failure occurs, so that the IO group can be shared. However, in order to specify the cause of the failure, it may be shared, but in order to specify the signal transmission source, it is more convenient to provide an IO group corresponding to each production facility without sharing.

  As described above, the alarm signal is a data signal that can specify what kind of failure, that is, the type of failure, in which production facility 12 together with the notification of the occurrence of the failure. In the present embodiment, as shown in FIG. 2, each alarm signal is registered in association with an IO group that is a failure generation source, that is, a production facility.

  In the present embodiment, it is necessary to prepare the diagnosis support information DB 26 having the above-described data structure in advance. However, unlike the diagnosis support information DB 202 prepared in advance in the past, the amount of data to be registered in advance, the workload required for registration, and the like are greatly reduced. In other words, an IO group is formed for each production facility, but the production facility to be monitored by this system and the type of status signal output by each production facility, as well as a failure that may occur in each production facility, that is, an alarm. The type of signal can be easily ascertained from a production facility specification or system design specification. That is, even a person who does not have specialized technology can set and register the status signal while classifying it for each production facility by referring to the above-mentioned specifications and the like, thereby forming an IO group. Furthermore, each IO group can be set and registered in association with an alarm signal. In addition, it is clear that the amount of data to be implemented in advance is smaller than that in the prior art since no information on the cause and treatment of the failure is input at the preliminary preparation stage. In other words, in the present embodiment, the workload required for the registration process in the preparatory stage can be reduced, and the system can be started up without inputting information on the cause / action of the failure. Moreover, since it is only necessary to input data in accordance with the specification document or the like when constructing the database, even a person who has no specialized knowledge or know-how can make advance preparations.

  Next, failure diagnosis processing for specifying the cause and treatment of the failure in the present embodiment will be described with reference to the flowchart shown in FIG. The failure diagnosis process is started after the occurrence of a failure is detected by the input of an alarm signal. Here, it is assumed that no failure has occurred yet after the introduction of the system, that is, no treatment result data is registered in the treatment result DB 27.

  The signal input unit 21 inputs an alarm signal and a status signal sent from the PLC 14 (step 110). Note that the status signal input to the signal input unit 21 is a status signal issued from all the production facilities connected to the PLC 14. The failure diagnosis processing unit 22 searches whether or not the treatment result data corresponding to the treatment result DB 27 is registered using the input alarm signal as a key (step 120). At this point in time when a failure occurs in any of the production facilities, no treatment result data is registered in the treatment result DB 27 (N in step 130). At this time, the factor / treatment input processing unit 23 And a treatment input screen are displayed (step 160). FIG. 5C shows an example of this factor and treatment input screen.

  By the way, the occurrence of the failure is notified to the monitoring center 1 by the failure occurrence notification processing unit 25, and the maintenance engineer who has received the notification of the occurrence of the failure goes to the site where the failure occurs according to the notification, and the cause of the abnormality The production equipment is put into a state where it can be operated. This is as described above. Conventionally, the contents of the treatment applied to the production facility where the failure has occurred are read out from the diagnosis support information DB 202 in which the treatment is pre-registered by a specialist engineer and presented. However, the maintenance engineer in charge is usually a person who performs maintenance and inspection of production equipment at the site, so he has the skill to identify the cause of the failure and take measures for repair. Should be. Therefore, in the present embodiment, when data concerning the cause and measures of failure is not registered in advance by a specialist engineer with an excessive workload, when the maintenance engineer handles the failure, The contents of treatment actually performed and the like are sequentially accumulated in the treatment result DB 27 as treatment result data.

  Accordingly, when the responsible maintenance staff arrives at the site and makes the faulty production facility operable, the maintenance engineer inputs the cause of the failure and the content of the treatment from the predetermined input screen displayed in step 160. Then, from the failure pattern input screen (not shown), the state signal type and ON / OFF / analog signal values that can specify the failure are input. Here, the type of status signal to be input and each ON / OFF / analog signal value refer to the status signal ON / OFF / analog signal value at the time of alarm occurrence. The maintenance engineer inputs corrections. Each value of the status signal that can specify a failure is referred to as a “failure pattern” as in the prior art. The status signals that can be input here are limited to the status signals that are set and registered in the IO group corresponding to the input alarm signal as shown in FIG. The maintenance engineer in charge can easily identify the faulty production facility if the alarm number on the input screen is confirmed in advance. The factor / procedure input processing unit 23 receives the factor and the treatment input by the maintenance engineer as described above (step 170).

  The failure diagnosis processing unit 22 acquires the alarm signal input from the PLC 14 and the date and time when the alarm signal was input, that is, the date and time when the failure occurred, and the failure pattern, the factor and the action are the factor / treatment input processing unit 23. Are recorded as treatment result data in the treatment result DB 27 (step 180). An example of the data format of the treatment result data recorded in the treatment result DB 27 is shown in FIG.

  In the present embodiment, the above-described process is repeated every time a new failure occurs, whereby treatment result data is sequentially accumulated in the treatment result DB 27.

  Subsequently, it is assumed that a new failure occurs after the occurrence of the failure. The failure diagnosis processing unit 22 searches the treatment result DB 27 using the alarm signal input due to the occurrence of the failure as a key (steps 110 and 120). As a result, the treatment result data of the same alarm signal is registered in the treatment result DB 27. (Y in step 130). Then, the failure diagnosis processing unit 22 refers to the diagnosis support information DB 26 and extracts the state signal included in the IO group corresponding to the same alarm signal as the input alarm signal from the input state signal. Then, each value of the extracted state signal is compared with a failure pattern included in each action result data of the same alarm number (step 140). As a result of the collation, when a failure pattern that matches the input state signal value is not recorded in the treatment result DB 27 (N in step 150), the factor / treatment input processing unit 23 displays a factor / treatment input screen. (Step 160). The processing flow of steps 110 to 160 described here may occur in the following cases.

  That is, it can be seen that a failure identified by the same alarm signal has occurred in the past as determined as “Y” in step 130. However, in this processing, although a failure having the same content has occurred in a certain production facility, since it is “N” in step 150, no failure has occurred due to the same factor. As a specific example, the reason why alarm number 1 has been input to the failure diagnosis device 20 in the past is because a failure has occurred in the electrodeposition lifter (alarm number 1) in a production facility called lifter (IO group 1). Assume that the cause of this failure is hanger deformation (for example, the failure pattern is X10 = ON, X22 = OFF, Y33 = ON). Since this failure has occurred in the past, the treatment result data corresponding to this failure is already registered in the treatment result DB 27. The reason why the alarm number 1 has been input to the failure diagnosis device 20 this time is that a failure has occurred in the electrodeposition lifter (alarm number 1) in the production facility called the lifter (IO group 1). Is a hanger separation (for example, the failure pattern is X12 = ON, X33 = ON, Y19 = ON). In such a case, the treatment result data corresponding to the alarm number 1 is registered in the treatment result DB 27 as illustrated above. However, because the failure pattern is different, the treatment result data hit in the comparison / collation processing in step 140 is Judged not to exist. Such a case may occur because the cause of the failure that the lifter does not drive may be due to the motor belt being cut or the power cable being cut, for example. This is because the number is not always limited to one.

  When the responsible maintenance staff arrives at the site and sets the malfunctioning production facility in an operable state, the maintenance engineer inputs the cause of the failure and the content of the treatment from the predetermined input screen displayed in step 160. Then, from the failure pattern input screen (not shown), the type of the state signal that can specify the failure and the signal value such as ON / OFF, that is, the failure pattern are input. Thereafter, as described above, the factor / treatment input processing unit 23 receives the factor and the treatment input by the maintenance engineer (step 170), and the failure diagnosis processing unit 22 receives the alarm signal, the failure occurrence date and time, The failure pattern, factor, and treatment are recorded in the treatment result DB 27 as treatment result data (step 180).

  As described above, even when the same failure occurs, treatment result data for different factors is sequentially accumulated in the treatment result DB 27.

  Subsequently, it is assumed that a new failure occurs after the occurrence of the failure. The failure diagnosis processing unit 22 searches the treatment result DB 27 using the alarm signal input due to the occurrence of the failure as a key (steps 110 and 120). As a result, the treatment result data of the same alarm signal is registered in the treatment result DB 27. (Y in step 130). Then, the failure diagnosis processing unit 22 compares and collates the input status signal with the failure pattern included in the treatment result data of the same alarm signal (step 140). As a result of this collation, when a failure pattern that matches the input state signal value is recorded in the treatment result DB 27 (Y in step 150), the display unit 24 displays the hit treatment result data on the screen (step 190). ). As a result, the worker in charge can confirm the displayed cause of the failure and the treatment for the repair as in the conventional case, so that the repair work can be started immediately. Then, the failure diagnosis processing unit 22 records the alarm signal, the failure occurrence date and time, the failure pattern, the factor, and the treatment as treatment result data in the treatment result DB 27 (Step 180). Here, the reason why the failure is recorded in the treatment result DB 27 is to make it possible to grasp the date and time of failure occurrence and the number of failure occurrences. Only the occurrence date and time may be recorded.

  As described above, in this embodiment, failure cause and treatment are not registered in advance by a specialist engineer, but treatment result data is sequentially registered when the maintenance engineer handles the failure. It is characterized by having gone. Certainly, when a failure due to a certain factor occurs for the first time, the factor / measure related to the failure is not registered in the database, so the maintenance engineer in charge needs to find out the cause of the failure himself and examine the treatment. come. Therefore, it may take more time to make the production facility operational than to simply refer to the action presented by the failure diagnosis apparatus and start repairing. However, failure factors and measures are accumulated in the treatment result DB 27 each time a failure is dealt with, so that the maintenance staff in charge sets and inputs the factors and measures only once.

  In this way, the input process by the maintenance engineer is required only for the first time. However, according to the present embodiment, the factor / action detailed data is associated with all the failure patterns and the respective failure patterns. System operation can be started without registration in the database in advance. In addition, it is possible to reduce the load of registration processing performed in advance.

  Also in this embodiment, pre-registration processing such as IO groups is required before the start of system operation, but the contents to be registered can be input with reference to the specifications, etc., so expertise and know-how for fault diagnosis Registration is possible even for those who do not have.

Embodiment 2. FIG.

  FIG. 7 is a block configuration diagram of failure diagnosis apparatus 20 in the present embodiment. The failure diagnosis apparatus 20 according to the present embodiment has a configuration in which a search processing unit 28 is provided instead of the factor / treatment input processing unit 23 of the first embodiment. In addition, since the other component may be the same, the same code | symbol is attached | subjected and description is abbreviate | omitted. The failure diagnosis device 20 searches the treatment result DB 27 based on the data input when a failure occurs, and determines the cause / treatment of the failure by specifying the treatment result data that matches the failure pattern. . In the first embodiment, when the matching treatment result data is not registered in the treatment result DB 27, the cause / treatment input processing unit 23 causes the user to input the cause / treatment of the failure. On the other hand, in the present embodiment, the search condition for the treatment result data can be set when the matching treatment result data is not registered. In other words, one of the treatment result data registered in the treatment result DB 27 can be effectively used.

  The overall configuration of the fault diagnosis and monitoring system in the present embodiment may be the same as the system configuration shown in FIG. Therefore, the description of the system configuration is omitted.

  Next, the failure diagnosis processing for identifying the cause and treatment of the failure in the present embodiment will be described using the flowchart shown in FIG. 8, and the same step number is assigned to the same processing as in the first embodiment, and the description will be given. Simplified or omitted as appropriate. As is clear from FIG. 8, the processing in the present embodiment is different from the processing in the first embodiment only when there is no treatment result data that matches in the comparison / collation processing in step 140 (step 210). The description will be given focusing on this processing. Therefore, in the present embodiment, a description will be given on the assumption that a certain amount of time has elapsed since the start of the operation of the system and a certain amount of treatment result data is accumulated in the treatment result DB 27.

  The failure diagnosis processing unit 22 searches the treatment result DB 27 using the alarm signal input due to the occurrence of the failure as a key (steps 110 and 120). As a result, the treatment result data of the same alarm signal is registered in the treatment result DB 27. (Y in step 130). Then, the failure diagnosis processing unit 22 refers to the diagnosis support information DB 26 and extracts the state signal included in the IO group corresponding to the same alarm signal as the input alarm signal from the input state signal. Then, each value of the extracted state signal is compared with a failure pattern included in each action result data of the same alarm number (step 140). As a result of this collation, when a failure pattern that matches the input state signal value is not recorded in the treatment result DB 27 (N in step 150), the search processing unit 28 executes the following search processing to detect a failure. The factors and measures are identified (step 210). This process will be described using the screen display example shown in FIG.

  When a failure pattern that matches the input status signal value is not recorded in the treatment result DB 27, the search processing unit 28 displays a submenu for selecting a search function as shown in FIG. To do. The conventional search has been provided conventionally and is not the gist of the present embodiment, and thus the description thereof is omitted. When the user selects the I / O diagnostic function, the screen display is switched to the search condition setting screen shown in FIG. Here, the search condition setting screen will be described.

  As shown in FIG. 5B, the search condition setting screen is divided into a search condition setting area located on the left side of the screen and a search result display area located on the right side of the screen. The search condition setting area is an area for setting a search condition for treatment result data in order to determine the cause and treatment of the failure. In the search result display area, the results searched under the search conditions set in the search condition setting area are displayed in a table format. As shown in the display example of the search condition setting area, in this embodiment, it is possible to set three types of search conditions of “relevance ratio”, “period”, and “facility / equipment”.

  “Performance rate” means the degree of coincidence between each value of the status signal specified by the failure pattern and the input status signal. That is, the failure pattern included in the treatment result data is composed of a plurality of state signals, but in the first embodiment, treatment result data including failure patterns that match each value of the input state signal to be compared is selected. Then, the factors and treatments included in the selected treatment result data were determined as the causes and treatments of the failure that occurred. That is, in the first embodiment, treatment result data is selected only when the relevance rate is 100% because it is a perfect match. On the other hand, in the present embodiment, treatment result data can be selected even when the relevance rate is not 100%. For example, when the number of status signals to be compared is 5, when the precision is lowered to 80%, treatment result data that matches 4 out of 5 is selected.

  In “Period”, a range of failure occurrence date and time is designated. The treatment result data belonging to the period specified here is selected.

  In "Equipment / Equipment", specify the device to be searched. If the alarm signal 1 is input when a failure occurs, in FIG. 2, treatment result data corresponding to the alarm signals 1 to n is selected for the same device. If it is other than the same device, treatment result data corresponding to other production facilities is selected. In the present embodiment, the same device and other than the same device are shown for convenience, but more detailed search conditions may be set, such as providing a submenu so that a production facility can be selected. .

  In the present embodiment, three types of search conditions can be set. However, other search conditions may be set. In the present embodiment, the case where any one is set will be described. However, the search condition may be specified by AND or OR.

  When the user sets the search condition and the execution button on the screen is selected, the search processing unit 28 retrieves the treatment result data that matches the designated condition by searching the treatment result DB 27 and displays the search result. List in area. At this time, the search processing unit 28 gives a selectable “diagnosis” button to each treatment result data to be displayed. When the user selects any button, the contents of the treatment result data are displayed on the screen. FIG. 5C is an example of this display. In the first embodiment, factors and treatments are input from this screen, but in this embodiment, the factors and treatments included in the treatment result data are displayed in a predetermined area. If the displayed factor and action are to be used, the “DB registration” button is selected. If the displayed factor and action are not adopted, the “return” button is selected, and the above-described search process is repeatedly executed.

  When the failure cause and the treatment are determined by the above search processing, the failure diagnosis processing unit 22 records the alarm signal, the failure occurrence date and time, the failure pattern, the factor and the treatment as treatment performance data in the treatment performance DB 27 (step). 180). Note that the alarm signal, the date and time of occurrence of the failure, and the failure pattern recorded here, in principle, use data such as an actually input alarm signal.

  According to this embodiment, even when treatment result data matching the input status signal or the like is not registered in the treatment result DB 27, the registered treatment result data can be set by enabling the search condition to be set. It can be used effectively.

  In each of the above embodiments, the failure diagnosis of the production facility installed in the factory 10 has been described as an example. However, the facility to be diagnosed is not limited to the production facility, for example, a building such as an elevator device. It can also be applied to failure diagnosis of equipment installed in the factory.

It is the block block diagram which showed Embodiment 1 of the failure diagnosis apparatus based on this invention. 6 is a diagram illustrating a data configuration example of a diagnosis support information DB according to Embodiment 1. FIG. 6 is a diagram showing an example data configuration of an IO group in the first embodiment. FIG. 4 is a flowchart showing a failure diagnosis process for specifying a cause and a measure of a failure in the first embodiment. FIG. 10 is a diagram showing a screen display example used when setting the cause and measure of failure in the first and second embodiments. It is the figure which showed the example of the data format of the treatment performance data recorded on treatment performance DB in Embodiment 1. FIG. It is the block block diagram which showed Embodiment 2 of the failure diagnosis apparatus based on this invention. 10 is a flowchart showing a failure diagnosis process for specifying a cause and a measure of a failure in the second embodiment. 1 is an overall configuration diagram of a failure diagnosis monitoring system using a failure diagnosis device. It is a block block diagram of the conventional failure diagnosis apparatus. It is the figure which showed the data structure registered into the diagnostic assistance information DB shown in FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Monitoring center, 2 Monitoring apparatus, 3 Public network, 10 factories, etc. 12 Production equipment, 14 PLC, 16 LAN, 20 Fault diagnostic device, 21 Signal input part, 22 Fault diagnostic processing part, 23 Factor / treatment input processing part, 24 display part, 25 failure occurrence notification processing part, 26 diagnosis support information DB, 27 treatment result DB, 28 search processing part.

Claims (3)

In a failure diagnosis apparatus that identifies a cause of a failure that has occurred in any of one or more facilities and presents a measure for the failure,
A signal input means for inputting an alarm signal that can specify the type of failure, and a status signal that indicates the status of each part of the equipment that is emitted from all equipment;
Means for storing a state signal group table for grouping and holding state signals that can be emitted by each facility;
Means for storing a failure group table that groups and holds types of failures that may occur in each facility;
Treatment result data storing action result data formed by combining the alarm signal value, the type and state value of the status signal necessary for specifying the cause of the failure, and the description data indicating the cause of the failure and the action against the failure Data storage means;
At the time of occurrence of a failure, among the state signals input by the signal input means, the state signals relating to the equipment in which the failure has occurred extracted with reference to each table, and the same alarm as the alarm signal input by the signal input means By comparing and collating each value with the status signal included in each treatment result data of the signal, the cause and action of the failure that occurred are identified, and the cause and action of the failure are identified as a result of the comparison and collation process If not, a factor / action presentation processing means for determining a status signal and its signal necessary for specifying the cause of the failure according to a user input operation, and description data indicating the cause of the failure and the action for the failure,
When the cause / treatment presentation processing means cannot identify the cause and action of the failure, new treatment result data is generated based on user input and input data from the signal input means, and stored in the treatment result data storage means. Treatment result data registration processing means to be registered;
A failure diagnosis apparatus characterized in that treatment result data is accumulated every time a new failure occurs.   When the cause / action presentation processing means cannot identify the cause and action of the failure, it inputs a status signal necessary for specifying the cause of the failure and description data indicating the failure cause and action for the failure to the user. The failure diagnosis apparatus according to claim 1, further comprising a factor / treatment input processing unit to be specified.   The factor / treatment presentation processing means compares and collates with the status signal extracted from the inputted status signal according to the search condition designated by the user when the failure factor and the treatment cannot be specified. The failure diagnosis apparatus according to claim 1, further comprising: a search processing unit that determines a cause and a measure of a failure that occurs while changing a range of treatment result data to be performed.

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