JP2007257581A - Failure analysis device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enable reliable and quick failure recovery by identifying a failed part of a failed device in consideration of the state of devices related to the failed device and the operating state of a plant. <P>SOLUTION: An error log collection means 16 collects error logs of devices and stores them in a device error log file 12, and a failure detection means 17 creates a device failure list in order of failure occurrence according to the error logs in the device error log file 12. A device configuration acquisition means 18 acquires other device configurations related to a failed device according to a device configuration information database 14, and a plant operating state acquisition means 19 acquires the operating state of the devices related to the failed device acquired by the device failure acquisition means 18. A failed device identification means 20 identifies the failed part of the failed device according to a device failure database 15, and a display means 21 displays out the identified failed part to a display device. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a failure analysis device that analyzes a failure of a device such as an arithmetic processing device that monitors and controls a plant.

  For example, a control device for controlling a plant is constituted by a processing unit such as a computer, and high reliability is required. Therefore, a self-diagnosis function is provided in the control device itself, and diagnosis is performed periodically, and the diagnosis result is stored in the memory as an error log. Then, failure analysis is performed based on the error log, failure recovery processing is performed, and the soundness of the control device is maintained.

  In general, the control device is composed of a plurality of substrates, and the function of the target for generating an error may be distributed across the plurality of substrates, and there is also a failure between the substrates. Therefore, when an error occurs, it is necessary to sequentially replace a plurality of substrates related to the error or to narrow down the connection portions of the substrates, so it takes a lot of time and effort to recover from the failure.

As a failure analysis device for a controller, there is one which narrows down a failure part so that restoration can be performed at an early stage and the burden on an operator can be reduced (for example, see Patent Document 1). This failure analysis device is built in the sequence controller, the failure analysis device has error log analysis means and a failure database, and an error log is registered in the memory. Then, the error log analysis means takes in the error log, refers to the failure database, and outputs information specifying the failure portion and the failure portion based on the corresponding probability to the outside as failure information. Further, the failure database stores in advance a failure location and failure probability for each error code in the database.
JP-A-10-124141

  However, the failure analysis apparatus of Patent Document 1 does not clearly identify the failure site, but prioritizes the occurrence of failure with probability and indicates the failure range, so the failure site cannot be clearly identified. As maintenance work to recover the failed part, it is necessary to consider the state of related equipment other than the failed part and the plant to be controlled. Therefore, if the failed part cannot be clearly identified, proper recovery work cannot be performed. .

  An object of the present invention is to provide a failure analysis device that can identify a failure site in a failure device in consideration of the state of the device related to the failure device and the operation state of the plant, and can perform reliable and quick failure recovery. is there.

  The failure analysis apparatus according to the present invention includes an error log collection unit that collects an error log of the device and stores the error log in a device error log file, and a failure detection unit that creates a device failure list in the order of failure occurrence based on the error log of the device error log file. And device configuration acquisition means for acquiring another device configuration related to the failed device based on the device configuration information database obtained by databaseizing the device configuration, and operation of the device related to the failed device acquired by the device failure acquisition means Identified by the plant operation state acquisition means for acquiring the state, the failure device identification means for identifying the failure part of the failure device based on the device failure database in which the error definition is classified into a database for each type of device, and the failure device identification means And a display means for displaying and outputting the faulty part.

  According to the present invention, it is possible to identify a true faulty device and its faulty part in consideration of the operation state of the device in the plant from the collected error log, so that a reliable and quick fault recovery can be performed. In addition, the failure device can quickly and specifically grasp the range of influence on plant operation. Even when the faulty device is a network device, it is possible to quickly grasp how far the plant operation is affected. In addition, it is possible to easily perform the substrate replacement work of the failure device.

(First embodiment)
FIG. 1 is a block diagram of a failure diagnosis apparatus according to the first embodiment of the present invention. The failure diagnosis device 11 includes a device error log file 12 for storing device errors, a device failure list 13 in which device failure information is stored in the order in which device errors occur, a device configuration information database 14 in which device configurations in the system are databased, It has a device failure database 15 in which error definitions are databased for each type of device.

  Further, an error log collecting unit 16 that collects device errors at a constant period and stores the device errors in the device error log file 12, and a failure detection unit 17 that detects a failed device from the device error log file 12 and creates a device failure list 13 in the order of failure occurrence. , Device configuration acquisition means 18 for acquiring a failed device from the device failure list 13 and acquiring another device configuration related to the device, plant operation state acquisition means 19 for acquiring an operation state of the device related to the failure device, A failure device identification unit 20 for identifying a failure part of the failure device based on the device failure database 15 and a display unit 21 for displaying the failure part of the identified device on a display device are provided.

  As shown in FIG. 2, the device error log file 12 is composed of items of device name, board type, failure occurrence time, and error information, and is a file that stores device error information collected from each device. As shown in FIG. 3, the device failure list 13 includes items of device name, board type, failure occurrence time, and error information, and device failure information is stored in the order of failure occurrence.

  As shown in FIG. 4, the device configuration information database 14 includes items of device name, board type, configuration, IN, and OUT, and uses the configuration information of the device configuration in the system as a database. This device configuration information database 14 has association information (IN, OUT) with other devices in addition to information related to the substrate configuration in the device. The association information (IN, OUT) with other devices is the input / output relationship (upstream / downstream relationship) of the device.

  As shown in FIG. 5, the device failure database 15 includes items of a substrate type, an error code, an error item, an error content, an analysis code, and related information, and uses an error definition as a database for each type of device. The apparatus failure database 15 is a database of error items defined for each board type, and causes of failure are defined as related information and analysis codes for the error items.

  The error log collection means 16 collects errors from the devices on the plant network at regular intervals and stores them in the device error log file 12. The failure detection means 17 detects a failure device from the device error log file 12 and creates a device failure list 13 in the order of failure occurrence. The device configuration acquisition unit 18 acquires a failed device from the device failure list 13 and acquires another device configuration related to the device. The plant operating state acquisition means 19 acquires the operating state of the device related to the malfunctioning device. The faulty device identification means 20 identifies the faulty part of the faulty device from the faulty device database 15 in which the faulty device, the device configuration, the operating state of the device, and the error definition of the device are defined. Then, the display means 21 displays and outputs the failure part of the device identified by the failure device identification means 20 on a display device (not shown).

  Next, the operation will be described. The failure detection unit 17 reads the device error log file 12 of each device periodically collected by the error log collection unit 16 and detects a device in which an error has occurred. When an apparatus in which an error has occurred is detected, apparatus error information is extracted from the apparatus error log file 12, and data is written in the apparatus failure list 13 in the order of occurrence time according to the data structure of the apparatus failure list 13 shown in FIG. Further, the apparatus configuration acquisition means 18 is notified of the occurrence of the apparatus error.

  The device configuration acquisition means 18 extracts devices that have generated device errors from the device failure list 13 in time series, and acquires configuration information of the failed devices from the device configuration information database 14. As shown in FIG. 4, the apparatus configuration information database 14 summarizes associations between information related to the board configuration in the apparatus and other apparatuses in a data database. The device configuration acquisition means 18 acquires board information and related information with other devices from the device configuration information database 14 for the device detected by the device error. The device configuration acquisition unit 18 passes the acquired device configuration information to the plant operation state acquisition unit 19.

  The plant operation state acquisition means 19 acquires the operation state of the apparatus based on the transferred apparatus information. The operation status of both systems of the device indicated as multi (duplex device) in the device configuration and the operation status of other devices related to the device in which a device error has occurred are acquired. The plant operating state acquisition means 19 delivers the operating state of the apparatus to the faulty apparatus identification means 20.

  The failure device identification means 20 acquires device error information of a device error from the device failure database 15 shown in FIG. The device failure database 15 is a database of error items defined for each board type. The cause of failure is defined as related information and an analysis code for the error item, and is grasped during operation when a device failure occurs. The cause of the error is replaced with the analysis code and output to the log.

  FIG. 6 is a flowchart showing the processing contents of failure identification inference in the failure device identification means 20. Based on this fault identification reasoning, the true device in which the fault has occurred is determined. First, as inference 1, it is determined whether the error information is related to another device (S1). This determination is performed by acquiring an error code from the device failure list 13 and determining whether or not it is a related code.

  If it is a related code, it becomes inference 2 and infers whether or not a failure has occurred in a device located upstream in the related device (S2). This inference is performed by determining whether or not the device set to IN in the device configuration information database 14 shown in FIG. If the device set to IN is present in the failure information of the device failure list 13, the true device in which the failure has occurred is replaced with the IN device described in the configuration information, and the process returns to step S1 (S3). That is, the relation with other devices is further inferred from the inference 1.

  If it is determined in step S2 that the device set to IN does not exist in the failure information of the device failure list 13, an inference 3 is “Is a device error device having a multi-configuration and an error related to duplication occurring?” Is determined (S4). This determination is similarly made from the error code, and if applicable, it is determined that the redundant device has failed (S5).

  If it is determined in step S4 that the device error is not a multi-configuration error related to duplication, it is determined that the individual device is faulty (S6). Further, when the error information is not related to other devices in the determination in step S1, it is determined that the individual device is faulty (S6).

  In this way, the device that has truly failed is determined. Based on the board type, error code, and error information of the failure information of the true failure device, the device failure database 15 is searched to extract the corresponding error item, error content, and related information, and the information is received by the display means 21. hand over. The display means 21 displays the received device information, base type, error code, error item, error content, and related information on a predetermined display device.

  According to the first embodiment, since a true faulty device and its faulty part in consideration of the operation state of the device in the plant can be identified from the device fault information collected by the error log collecting means 16, it is highly reliable and quick. Fault recovery is possible.

(Second Embodiment)
FIG. 7 is a block diagram of a failure analysis apparatus according to the second embodiment of the present invention. This second embodiment is different from the first embodiment shown in FIG. 1 in that the device management information database 22 is a database of the scope of control of each device (control target devices and process input / output). In addition, a failure influence range estimation means 23 for estimating an influence on a plant by a failure device whose failure site has been identified by the failure device identification means 20 based on the device management information database 22 is provided. The same elements as those in FIG. 1 are denoted by the same reference numerals, and redundant description is omitted.

  When the true faulty device is determined, the device fault identification unit 20 displays the fact on the display device 20 and transfers the faulty device information to the fault influence range estimation unit 23. The failure influence range estimation means 23 acquires the device defined as OUT connected to the failed device from the device failure database 15. The operating status of the faulty device and the device defined as OUT is acquired from the plant operating status acquisition means 19. In addition, system, device, and process I / O information is extracted from the device management information database 22 from device failure and device management information of the device defined as OUT.

  FIG. 8 is a data configuration diagram of the device management information database 22. As shown in FIG. 8, the device management information database 22 is composed of items of device name, system, device, and process I / O, and the scope of control of each device (control target device and process input / output) is stored in the database. It has become. In other words, the device management information database 22 is a database in which process input / output signals that are handled in advance by the system, the device that performs control, and other devices are defined for each device.

  The failure influence range estimation means 23 obtains from the device management information database 22 based on the operation state of the device related to the failed device and the device configuration information (whether or not it is a multi-configuration), and the device stops or is located upstream. If the device to be stopped is stopped, the information is transferred to the display means 21.

  Based on the device information delivered from the failure influence range estimation unit 23, the display unit 21 displays on the predetermined display device the system affected by the device stop, the uncontrollable device, and the process input / output range.

  According to the second embodiment, in addition to the effects of the first embodiment, the failure influence range estimation means 23 can be used to quickly and specifically grasp the influence range on the plant operation by the failure device, so Quick failure recovery is possible while minimizing adverse effects.

(Third embodiment)
FIG. 9 is a block diagram of a failure analysis apparatus according to the third embodiment of the present invention. This third embodiment is different from the second embodiment shown in FIG. 7 in that a network configuration information database 24 in which the relationship between network configuration devices and devices on the network is databased and a faulty device identification means 20. In the case where the faulty device whose fault site is identified in FIG. 5 is a network device, the influence of the network fault is estimated based on the network configuration information database 24, and the affected device is output to the fault influence range estimation means 23. 25. The same elements as those in FIG.

  In FIG. 9, the network configuration information database 24 is a database of associations between network configuration devices and devices on the network, and the network influence range estimation means 25 is a fault whose fault site has been identified by the faulty device identification means 20. When the device is a network device, the influence of the network failure is estimated based on the network configuration information database 24, and the affected device is output to the failure influence range estimation means 23.

  When the device includes a network device, as shown in FIG. 10, the device configuration information database 14 defines a “router” that is a network configuration device for connecting the devices, and the board type is “NET”. Define device configuration information as a wide range of configuration information definition database.

  FIG. 11 is a data configuration diagram of the network configuration information database 24 according to the third embodiment of this invention. As shown in FIG. 11, the network configuration information database 24 includes items of device name, upper network device, lower network device, and connection device, and network devices (routers and the like) that connect networks of different layers are stored in layers. It is a database that defines hierarchical relationships with connections, and further defines devices connected to individual networks. The network configuration information database 24 provides information on the upper network device, the lower network device, and the connection device as the configuration information of the failed network device.

  Next, the operation will be described. When the true faulty device is determined, the device fault identification unit 20 displays the fact on the display device 20 and, when the board type of the faulty device is “NET”, the network fault influence range estimation unit. 25, the network device information is transferred.

  The network failure influence range estimation unit 25 acquires information on the upper network device, the lower network device, and the connection device as the configuration information of the failed network device from the network configuration information database 24. Further, the network failure influence range estimation means 25 grasps a device connected to the network managed by the failed network device. If there is a network device located below the failed network device, the device managed by the network device located further below is grasped.

  In this way, devices connected to all lower networks are grasped, and the range of influence on devices due to network failures is determined. The affected device is transferred to the failure influence range estimation means 23. Since the processing after this is the same as that of the failure influence range estimation means 23 of the second embodiment, description thereof is omitted. As a result, it is possible to display a failure influence range due to a failure of a network device on the network.

  According to the third embodiment, in addition to the effects of the second embodiment, the network influence range estimation means 25 can quickly transmit to the extent that the faulty device affects the plant operation even in the case of a network equipment failure. The situation can be easily grasped.

(Fourth embodiment)
FIG. 12 is a block diagram of a failure analysis apparatus according to the fourth embodiment of the present invention. This fourth embodiment is different from the second embodiment shown in FIG. 7 in that the failure part of the failure device whose failure part is identified by the failure device identification means based on the device configuration information database is replaced. A faulty device board replacement judging means 26 for judging whether or not it is possible is provided. The same elements as those in FIG.

  In FIG. 12, the failure device board replacement determination means 26 determines the replacement of the failure part (substrate etc.) of the failure device after the influence range is determined by the failure influence range estimation means 23, and the determination result of the failure device is the determination result. The board replacement information is displayed on the display device by the display means 21.

  That is, the faulty device board replacement determination unit 26 refers to the device configuration information database 14 based on the information on the faulty device and faulty board identified by the fault influence range estimation unit 23, and duplicates the configuration information of the corresponding device. It is determined whether or not the faulty substrate can be replaced by determining the relationship with other devices from the information of IN and OUT. The determined result is displayed on the display device from the display means 21.

  According to the fourth embodiment, in addition to the effects of the second embodiment, the failure device substrate replacement determination means 26 outputs a determination result indicating whether the failed substrate of the failed device can be replaced. It can be a help when performing repairs, and quick failure recovery is possible.

(Fifth embodiment)
FIG. 13 is a block diagram of a failure analysis apparatus according to the fifth embodiment of the present invention. This fifth embodiment is different from the fourth embodiment shown in FIG. 12 in that the faulty part is identified by the faulty device identification means based on the spare part management database 27 and the spare part management database 27. A replacement board spare part confirmation unit 28 for confirming a replacement spare part of a faulty part of the faulty device is provided. The same elements as those in FIG.

  In FIG. 13, a spare part management database 27 in which the number of spare parts of a board for each apparatus is made into a database and a replacement board spare part confirmation means 28 for confirming a replacement spare part of a failed part (a board or the like) of a failed device are added. Is provided.

  As shown in FIG. 14, the spare part management database 27 is composed of items of device name, board type, number of spares, and version. Further, the apparatus configuration database 14 is provided with board version information as shown in FIG.

  The replacement board spare part confirmation means 28 confirms the number of spare parts and the version of the corresponding board from the spare part management database 27 for the board of the apparatus determined to be replaceable by the failed device board replacement judgment means 26, and the device configuration. Based on the version information of the board held in the database 14, the matching between the spare board and the version of the mounting board is determined, and the current holding amount of the replacement board is displayed on the display device via the display means 21. Thereby, confirmation of the replacement spare part of the failure part of a failure apparatus can be performed easily.

  In the above description, the case where the device configuration information database 14 does not have a “router” that is a network configuration device for connecting devices is described. However, as in the third embodiment shown in FIG. When the configuration information database 34 and the network influence range estimation means 25 are provided, a “router” or the like that is a network configuration device of the network connecting the devices is defined in the device configuration information database 14 and the board type is “NET”. To define the device configuration information as a wide range of configuration information definition database. In this case, “router” is also defined in the spare part management database 27.

  According to the fifth embodiment, in addition to the effects of the fourth embodiment, the replacement substrate spare part confirmation means 28 checks the spare part of the failed device. Will help.

1 is a block configuration diagram of a failure diagnosis apparatus according to a first embodiment of the present invention. The data block diagram of the apparatus error log file in the failure diagnosis apparatus concerning the 1st Embodiment of this invention. The data block diagram of the apparatus failure list | wrist in the failure diagnosis apparatus concerning the 1st Embodiment of this invention. The data block diagram of the apparatus structure information database in the failure diagnosis apparatus concerning the 1st Embodiment of this invention. The data block diagram of the apparatus failure database in the failure diagnosis apparatus concerning the 1st Embodiment of this invention The flowchart which shows the processing content of the fault identification reasoning in the fault device identification means of the fault diagnosis apparatus concerning the 1st Embodiment of this invention. The block block diagram of the failure analysis apparatus which concerns on the 2nd Embodiment of this invention. The data block diagram of the apparatus management information database of the failure analysis apparatus which concerns on the 2nd Embodiment of this invention. The block block diagram of the failure analysis apparatus which concerns on the 3rd Embodiment of this invention. The data block diagram of the apparatus structure information database of the failure analysis apparatus which concerns on the 3rd Embodiment of this invention. The data block diagram of the network configuration information database of the failure analysis apparatus which concerns on the 3rd Embodiment of this invention. The block block diagram of the failure analysis apparatus which concerns on the 4th Embodiment of this invention. The block block diagram of the failure analysis apparatus which concerns on the 5th Embodiment of this invention. The data block diagram of the spare part management database of the failure analysis apparatus which concerns on the 5th Embodiment of this invention. The data block diagram of the apparatus structure database of the failure analysis apparatus which concerns on the 5th Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 ... Failure diagnosis device, 12 ... Device error log file, 13 ... Device failure list, 14 ... Device configuration information database, 15 ... Device failure database, 16 ... Error log collection means, 17 ... Failure detection means, 18 ... Device configuration acquisition Means 19 ... Plant operating state acquisition means 20 ... Faulty device identification means 21 ... Display means 22 ... Device management information database 23 ... Fault influence range estimation means 24 ... Network configuration information database 25 ... Network influence range estimation Means 26... Faulty device board replacement judgment means 27. Spare part management database 28. Replacement board spare part confirmation means

Claims (5)

Error log collecting means for collecting device errors and storing them in a device error log file, failure detecting means for creating a device failure list in the order of failure occurrence based on the error log of the device error log file, and device having a device configuration in a database Device configuration acquisition means for acquiring another device configuration related to the faulty device based on the configuration information database, and plant operation state acquisition means for acquiring the operating status of the device related to the faulty device acquired by the device fault acquisition means And a faulty device identifying means for identifying a faulty part of the faulty device based on a device fault database in which error definitions for each type of equipment are databased, and a display means for displaying and outputting the faulty part identified by the faulty device identifying means; A failure analysis apparatus comprising: A failure influence range estimation means for estimating an influence on the plant by the faulty device whose fault site has been identified by the faulty device identification means based on a device management information database in which the plant control range of each device is databased; The failure analysis apparatus according to claim 1, wherein: When the failure device whose failure location has been identified by the failure device identification means is a network device, the influence of the network failure is estimated based on a network configuration information database in which the relationship between network configuration devices and devices on the network is databased. 3. The failure analysis apparatus according to claim 2, further comprising network influence range estimation means for outputting the affected device to the failure influence range estimation means. The failure device board replacement determination unit for determining whether or not the failure site of the failed device whose failure site is identified by the failed device identification unit based on the device configuration information database can be replaced. The failure analysis apparatus according to any one of 1 to 3. A replacement board spare part confirmation unit for confirming a replacement spare part of a faulty part of the faulty device whose faulty part has been identified by the faulty unit identification unit based on a spare part management database in which the number of spare parts of the board in units of devices is made into a database. The failure analysis device according to claim 1, wherein the failure analysis device is a failure analysis device.

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