JP2013168859A - Process input/output device diagnosis system, process input/output control apparatus and process input/output device diagnosis method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To present the accuracy of a process input/output device precisely by verifying robustness of the process input/output device during operation of plant equipment.SOLUTION: A reference signal reader 20 reads an analog signal from plant equipment 2 in response to a read request and outputs an analog signal. A process input/output device 10 reads the analog signal from the plant equipment 2 in response to a read request, converts an analog value represented by the analog signal into a digital value through A/D conversion and outputs a digital signal representing the digital value. A diagnosis apparatus 30 outputs the read request, calculates a reference digital value from the analog value represented by the analog signal from the reference signal reader 20, calculates an error between the digital value represented by the digital signal from the process input/output device 10 and the reference digital value, generates a determination result representing whether the error is settled within a reference range, and outputs diagnosis information containing the error, the determination result and determination reference information to an output device 34.

Description

  Embodiments described herein relate generally to a process input / output device diagnosis system, a process input / output control device, and a process input / output device diagnosis method.

  Plant equipment in nuclear power plants is operated with an operation period of more than 10 months and a periodic inspection period of several months. In the periodic inspection period, the plant equipment operated during the operation period is stopped, and many items are inspected for the purpose of “confirming soundness”, “maintaining functions” and “improving reliability” of the plant equipment.

  In the operation period, it is necessary to verify “soundness check”, “function maintenance” and “reliability improvement” of the plant equipment in operation. For this verification, a plant monitoring device for monitoring plant equipment is provided. The plant monitoring device does not need to be provided in the nuclear power plant, and is provided in a remote place via a network. Thereby, the worker can monitor the plant equipment from a remote place by the plant monitoring device.

  The signal received by the plant monitoring apparatus via the network is preferably a digital signal instead of an analog signal output from the plant equipment. Therefore, a process input / output device that converts an analog signal output from the plant equipment into a digital signal is provided between the plant equipment and the plant monitoring device.

  The plant monitoring device monitors the plant equipment based on the digital signal output from the process input / output device, and the worker uses the monitoring results to “check the soundness” and “maintain the function” of the operating plant equipment. And verify "improving reliability". Therefore, in order to verify these, it is necessary to verify whether or not the process input / output device correctly performs A / D conversion, that is, the soundness of the process input / output device.

  In the technique described in Patent Document 1, a main microcomputer converts an analog value to a first digital value by A / D conversion, and a sub microcomputer converts the analog value to a second digital value by A / D conversion. The soundness of the process input / output device is confirmed based on whether or not the difference between the first digital value and the second digital value is within the reference range. Patent Document 2 describes a method of determining whether a sensor or the like is disconnected based on time.

JP 2007-300469 A JP 2009-135655 A

  The conventional process input / output device diagnostic system verifies the soundness of the process input / output device by checking whether the error between the stop digital value and the reference digital value is within the reference range. can do. However, in the conventional process input / output device diagnosis system, when verifying the soundness of the process input / output device, the plant equipment is stopped. For this reason, the soundness of the process input / output device when the plant equipment is in operation during the operation period has not been verified.

  In the operation period, when the operation of the plant equipment is prolonged, the operation of the process input / output device is also prolonged. For this reason, the error between the stop time digital value of the process input / output device and the reference digital value is within the reference range. In this case, the error may deviate immediately after operating the plant equipment during the operation period. That is, the accuracy of the process input / output device is reduced. Therefore, it is desirable to present the accuracy of the process input / output device in detail so that the process input / output device can be dealt with early.

  When the accuracy of the process input / output device decreases, the digital signal output from the process input / output device does not represent a correct digital value. In this case, the plant monitoring device cannot receive a correct digital signal from the process input / output device. Therefore, when the operator operates the plant equipment using the digital signal, there is a possibility of causing an erroneous operation.

  The problem to be solved by the present invention is to verify the soundness of the process input / output device during operation of the plant equipment and to present the accuracy of the process input / output device in detail.

  A process input / output device diagnosis system according to an embodiment includes a plant device that outputs an analog signal representing an analog value, and a process input / output that is connected to the plant device and includes a reference signal reader, a process input / output device, and a diagnosis device. The reference signal reader reads the analog signal from the plant equipment and outputs the analog signal in response to the read request, and the process input / output device responds to the read request. In response, a process input unit that reads the analog signal from the plant equipment, an A / D conversion unit that converts the analog value represented by the analog signal into a digital value by analog / digital (A / D) conversion, and A process output unit that outputs a digital signal representing a digital value to the diagnostic device, and the diagnostic device reads the reading Output to the process input / output device and the reference signal reader, receive the analog signal from the reference signal reader, and receive the digital signal from the process input / output device; and the analog signal represents the acquisition unit An accuracy determination unit that calculates a reference digital value from an analog value, calculates an error between the digital value represented by the digital signal and the reference digital value, and generates a determination result; the error, the determination result, and determination reference information An output control unit that outputs diagnostic information including: to the output device, and the determination result indicates that the error is within a reference range from a preset lower limit value to a preset upper limit value. Reference range information, upper limit deviation information indicating that the error is equal to or greater than the upper limit value, and lower limit deviation information indicating that the error is equal to or less than the lower limit value. If, represents any of the determination criterion information of said diagnostic information includes the lower limit deviation information, and the reference range information, and a upper limit deviation information, it is characterized.

  The process input / output control device of the embodiment is a device connected to plant equipment that outputs an analog signal representing an analog value, and includes a reference signal reader, a process input / output device, and a diagnostic device, The reference signal reader reads the analog signal from the plant equipment in response to a read request and outputs the analog signal, and the process input / output device responds to the read request from the plant equipment. A process input unit that reads an analog signal, an A / D conversion unit that converts the analog value represented by the analog signal into a digital value by analog / digital (A / D) conversion, and a digital signal that represents the digital value A process output unit for outputting to the apparatus, and the diagnostic apparatus sends the read request to the process input / output apparatus and the reference Output to the signal reader, receiving the analog signal from the reference signal reader, obtaining the digital signal from the process input / output device, and calculating a reference digital value from the analog value represented by the analog signal, An error determination unit that calculates an error between the digital value represented by the digital signal and the reference digital value and generates a determination result; and outputs diagnostic information including the error, the determination result, and determination reference information to an output device An output control unit, wherein the determination result is information within a reference range indicating that the error is within a reference range from a preset lower limit value to a preset upper limit value, and the error is The upper limit deviation information indicating that the error is equal to or higher than the upper limit value, and the lower limit deviation information indicating that the error is equal to or lower than the lower limit value. Constant reference information includes the lower limit deviation information, and the reference range information, and a upper limit deviation information, it is characterized.

  The process input / output device diagnosis method of the embodiment includes a process input / output control device that is connected to a plant device that outputs an analog signal representing an analog value and includes a process input / output device, a reference signal reader, and a diagnosis device. A method of diagnosing the process input / output device, wherein the reference signal reader reads the analog signal from the plant equipment in response to a read request, and outputs the analog signal to the diagnostic device; The process input / output device reads the analog signal from the plant equipment in response to the read request, and the process input / output device converts the analog value represented by the analog signal to analog / digital (A / D). ) Converting to a digital value by conversion; and the process input / output device includes a data representing the digital value. A diagnostic signal output to the diagnostic device, the diagnostic device outputs the read request to the process input / output device and the reference signal reader, receives the analog signal from the reference signal reader, and the process Receiving the digital signal from the input / output device; and the diagnostic device calculates a reference digital value from the analog value represented by the analog signal, and calculates an error between the digital value represented by the digital signal and the reference digital value. Calculating and generating a determination result, and the diagnostic device outputting diagnostic information including the error, the determination result, and determination criterion information to an output device, and the determination result includes: Reference range information indicating that the error is within a reference range from a preset lower limit value to a preset upper limit value, and the error Represents upper limit deviation information indicating that the error is equal to or greater than the upper limit value, and lower limit deviation information indicating that the error is equal to or less than the lower limit value, and the criterion information of the diagnosis information includes the lower limit information Deviation information, the reference range information, and the upper limit deviation information are included.

  According to the present invention, the soundness of a process input / output device can be verified during operation of plant equipment, and the accuracy of the process input / output device can be presented in detail.

It is a block diagram which shows the structure of the process input / output apparatus diagnostic system of 1st Embodiment. It is a flowchart which shows operation | movement of the process input / output apparatus diagnostic system of 1st Embodiment. It is a figure which shows the reference range information, upper limit deviation information, and lower limit deviation information. It is a figure which shows the information in a reference | standard range (information within a prediction range, the prediction range upper limit deviation information, and a prediction range lower limit deviation information), upper limit deviation information, and lower limit deviation information. It is a block diagram which shows the structure of the process input / output apparatus diagnostic system of 2nd Embodiment. It is a figure which shows the execution time of a reference signal reader and the delay time of the signal by wiring, and the execution time of the process input / output device and the delay time of the signal by wiring. It is a flowchart which shows operation | movement of the process input / output apparatus diagnostic system of 2nd Embodiment. It is a figure which shows the reading period of the signal of a reference signal reader and a process input / output device. It is a flowchart which shows the detail of the resending process (step S30) of FIG. FIG. 9 is a flowchart showing details of the retransmission processing (step S30) in FIG. 7 and shows an example different from FIG. It is a block diagram which shows the structure of the process input / output apparatus diagnostic system of 3rd Embodiment. It is a flowchart which shows operation | movement of the process input / output apparatus diagnostic system of 3rd Embodiment. It is a flowchart which shows the prediction diagnosis process (step S40) of FIG. It is a flowchart which shows operation | movement of the process input / output apparatus diagnostic system of 4th Embodiment. It is a flowchart which shows the output process (step S50) of FIG. It is a figure which shows the example of the special symbol provided to diagnostic information. It is a block diagram which shows the structure of the process input / output apparatus diagnostic system of 5th Embodiment. It is a flowchart which shows operation | movement of the process input / output apparatus diagnostic system of 5th Embodiment. It is a graph which shows a linear characteristic when the range of an analog value is 1-5 [V], and the range of a digital value (digital conversion value) is 0-4000.

  Embodiments of a process input / output device diagnosis system according to the present invention will be described below with reference to the drawings. Here, the same or similar parts are denoted by common reference numerals, and redundant description is omitted.

[First Embodiment]
FIG. 1 is a block diagram illustrating a configuration of a process input / output device diagnosis system according to the first embodiment.

  The process input / output device diagnosis system of the first embodiment includes a plant device 2, a process input / output control device 1, and a plant monitoring device 3. The plant monitoring device 3 is connected to the process input / output control device 1 via a network.

  The plant equipment 2 outputs an analog signal representing an analog value. The process input / output control device 1 outputs a digital signal representing a digital value based on the analog signal output from the plant equipment 2.

  The plant monitoring device 3 receives the digital signal output from the process input / output control device 1 and monitors the plant equipment 2 based on the digital value represented by the digital signal. Monitoring of the plant equipment 2 includes whether or not the plant equipment 2 is operating or whether or not the digital value is within a predetermined range. Moreover, the plant monitoring apparatus 3 is provided with the display apparatus which displays a digital value, and the worker may monitor the plant apparatus 2 with the digital value displayed on the display apparatus.

  The process input / output control device 1 includes a process input distributor 4, a reference signal reader 20, a process input / output device 10, and a diagnostic device 30.

  The process input distributor 4 connects the plant equipment 2 with the process input / output device 10 and the reference signal reader 20, and the analog signal output from the plant equipment 2 is sent to the process input / output device 10 and the reference signal reader 20. Output. The process input distributor 4 may be provided outside the process input / output control apparatus 1 or may be provided inside.

  The diagnosis device 30 is connected to the process input / output device 10 and the reference signal reader 20 and diagnoses the process input / output device 10.

  The process input / output device 10 includes a process input unit 11, an A / D conversion unit 12, and a process output unit 13. The operation of each component of the process input / output device 10 will be described later.

  Each component of the process input / output device 10 is configured by hardware or software. For example, when each component of the process input / output device 10 is software, the programmable controller system according to the first embodiment further includes a first computer. The first computer includes a storage unit that stores the first computer program, and a CPU (Central Processing Unit) that reads the first computer program from the storage unit and executes the first computer program. The first computer program realizes the function of each component of the process input / output device 10 to be described later.

  The diagnostic device 30 includes an acquisition unit 31, an accuracy determination unit 32, an output control unit 33, and an output device 34. The operation of each component of the diagnostic device 30 will be described later.

  Each component of the diagnostic device 30 is configured by hardware or software. For example, when each component of the diagnostic device 30 is software, the programmable controller system according to the first embodiment further includes a second computer. The second computer includes a storage unit that stores the second computer program, and a CPU that reads the second computer program from the storage unit and executes the second computer program. The second computer program realizes the function of each component of the diagnostic device 30 described later.

  FIG. 2 is a flowchart showing the operation of the process input / output device diagnosis system of the first embodiment.

  The acquisition unit 31 of the diagnostic device 30 outputs a read request to the process input / output device 10 and the reference signal reader 20 (steps S1 and S2).

  The reference signal reader 20 reads the analog signal from the plant equipment 2 in response to the reading request, and outputs the analog signal to the diagnostic device 30 (step S3).

  The process input unit 11 of the process input / output device 10 reads an analog signal from the plant equipment 2 in response to the read request (step S4). At this time, the A / D converter 12 converts the analog value represented by the analog signal into a digital value by analog / digital (A / D) conversion (step S5). The process output unit 13 outputs a digital signal representing a digital value to the diagnostic device 30 and the plant monitoring device 3 (step S6).

  The acquisition unit 31 of the diagnostic device 30 receives an analog signal from the reference signal reader 20 (step S7), and receives a digital signal from the process input / output device 10 (step S8).

  The accuracy determination unit 32 of the diagnostic device 30 calculates a reference digital value from the analog value represented by the analog signal (step S9).

  Next, the accuracy determination unit 32 calculates an error “γ [%]” between the digital value represented by the digital signal and the reference digital value (step S10). Next, the accuracy determination unit 32 determines whether or not the error “γ” is within the reference range (step S11).

  The reference range is a range from a preset lower limit value “−α [%]” to a preset upper limit value “+ α [%]”. In step S11, the accuracy determination unit 32 generates a determination result indicating whether or not the error “γ” is within the reference range “−α <γ <+ α”. This determination result represents any of the reference range information, the upper limit deviation information, and the lower limit deviation information.

  FIG. 3 is a diagram illustrating the reference range information, the upper limit deviation information, and the lower limit deviation information.

  The reference range information indicates that the error “γ” is larger than the lower limit value “−α” and smaller than the upper limit value “+ α” (“−α <γ <+ α”).

  The upper limit deviation information indicates that the error “γ” is greater than or equal to the upper limit value “+ α” (“+ α ≦ γ”).

  The lower limit deviation information indicates that the error “γ” is equal to or lower than the lower limit value “−α” (“γ ≦ −α”).

  The output control unit 33 of the diagnostic device 30 outputs diagnostic information to the output device 34 (step S12). The diagnostic information includes a digital signal, an analog signal, a reference digital value, an error “γ”, a determination result, and determination criterion information. The criterion information includes lower limit deviation information “γ ≦ −α”, reference range information “−α <γ <+ α”, and upper limit deviation information “+ α ≦ γ”. When the output device 34 is a display device, the output control unit 33 displays the contents of the diagnostic information on the display device in character notation.

  FIG. 19 is a graph showing linear characteristics when the analog value range is 1 to 5 [V] and the digital value (digital conversion value) range is 0 to 4000. The error “γ” is obtained by {(digital conversion value−reference digital value) ÷ reference digital value × 100}.

  Now, assume that the analog value represented by the analog signal from the reference signal reader 20 is 2 [V], and the digital value represented by the digital signal from the process input / output device 10 is 1025. According to the linear characteristic, when the analog value is 2 [V], the reference digital value is 1000. Therefore, the error “γ” becomes 2.5% by {(1025−1000) ÷ 1000 × 100}. Here, when “α” is set to “3”, the worker can limit the error “γ” even when the error “γ” is within the reference range “−α <γ <+ α”. It can be confirmed that the deviation is close.

  Thus, according to the present embodiment, the diagnostic device 30 outputs the above-described diagnostic information to the output device 34, so that the diagnostic information is presented to the worker. At this time, in addition to the error “γ” and the determination result, the diagnosis information includes determination criterion information (lower limit deviation information “γ ≦ −α”, reference range information “−α <γ <+ α”, and upper limit deviation). Information “+ α ≦ γ”). For this reason, the worker refers to the determination criterion information output to the output device 34, so that the error “γ” between the digital value of the process input / output device 10 and the reference digital value is within the reference range “−α <γ <. Even if it is within + α ”, it can be confirmed whether or not the error“ γ ”is close to the deviation. Therefore, the worker can deal with the process input / output device 10 at an early stage before the accuracy of the process input / output device 10 decreases. Thus, according to the present embodiment, the accuracy of the process input / output device 10 can be presented to the worker in detail.

  In the present embodiment, the soundness of the process input / output device 10 is verified without stopping the plant equipment 2. Therefore, according to the present embodiment, the soundness of the process input / output device 10 can be verified during operation of the plant equipment 2, and the accuracy of the process input / output device 10 can be presented to the worker in detail.

  Further, in the present embodiment, the determination criterion by the accuracy determination unit 32 of the diagnostic device 30 is within the above-described reference range “−α <γ <+ α”, but the determination criterion can be made stricter. In that case, the accuracy determination unit 32 further determines whether or not the error “γ” is within the prediction reference range.

  The prediction reference range is a predicted warning upper limit value “+ α−β which is smaller than the upper limit value“ + α [%] ”from a predicted warning lower limit value“ −α + β [%] ”which is larger than the lower limit value“ −α [%] ”. [%] ”. Here, “β” is smaller than “α”. In step S11, the accuracy determination unit 32 determines whether or not the error “γ” is within the reference range “−α <γ <+ α”. When the error “γ” is within the reference range “−α <γ <+ α”, the accuracy determination unit 32 determines whether the error “γ” is within the prediction reference range “−α + β <γ <+ α−β”. And a determination result is generated. This determination result represents one of the prediction range information, the prediction range upper limit deviation information, and the prediction range lower limit deviation information.

  FIG. 4 is a diagram showing reference in-range information (prediction range information, prediction range upper limit deviation information, and prediction range lower limit deviation information), upper limit deviation information, and lower limit deviation information.

  The prediction range information indicates that the error “γ” is larger than the predicted warning lower limit value “−α + β” and smaller than the predicted warning upper limit value “+ α−β” (“−α + β <γ <+ α−β”). "). The upper limit deviation information within the prediction range indicates that the error “γ” is equal to or larger than the prediction alarm upper limit value “+ α−β” and smaller than the upper limit value “+ α” (“+ α−β ≦ γ <+ α”). . The prediction range lower limit deviation information indicates that the error “γ” is larger than the lower limit value “−α” and is less than or equal to the predicted alarm lower limit value “−α + β” (“−α <γ ≦ −α + β”). .

  Therefore, when the determination result indicates the reference range information “−α <γ <+ α”, the reference range information “−α <γ <+ α” is the predicted range information “−α + β <γ <+ α”. -Β ", prediction range upper limit deviation information" + α-β≤γ <+ α ", and prediction range lower limit deviation information" -α <γ≤-α + β ". In this case, in step S11, the criterion information of the diagnostic information further includes prediction range lower limit deviation information “−α <γ ≦ −α + β” and prediction range information “−α + β <γ <+ α−β”. Prediction range upper limit deviation information “+ α−β ≦ γ <+ α” is included.

  Now, assume that the analog value represented by the analog signal from the reference signal reader 20 is 2 [V], and the digital value represented by the digital signal from the process input / output device 10 is 1025. According to the linear characteristics shown in FIG. 19, when the analog value is 2 [V], the reference digital value is 1000. Therefore, the error “γ” becomes 2.5% by {(1025−1000) ÷ 1000 × 100}. Here, when “α” is set to “3” and “β” is set to “1”, the worker has the error “γ” within the reference range “−α <γ <+ α”. Even in this case, when the error “γ” is in “+ α−β ≦ γ <+ α”, it can be confirmed that the deviation is close to the limit.

  Thus, according to the present embodiment, in addition to the error “γ” and the determination result, the diagnosis information includes determination criterion information (lower limit deviation information “γ ≦ −α”, reference range information “−α <γ <+ Α ”, upper limit deviation information“ + α ≦ γ ”), and the reference range information“ −α <γ <+ α ”is within the prediction range lower limit deviation information“ −α <γ ≦ −α + β ”, within the prediction range. It includes information “−α + β <γ <+ α−β” and prediction range upper limit deviation information “+ α−β ≦ γ <+ α”. For this reason, the worker refers to the determination criterion information output to the output device 34, whereby the error “γ” between the digital value of the process input / output device 10 and the reference digital value is within the reference range “−α <γ < Even when it is within + α, when the error “γ” is “−α <γ ≦ −α + β” or “+ α−β ≦ γ <+ α”, it can be confirmed that the deviation is almost as close as possible. Therefore, the worker can deal with the process input / output device 10 at an early stage before the accuracy of the process input / output device 10 decreases. As described above, according to the present embodiment, the soundness of the process input / output device 10 can be verified during operation of the plant equipment 2, and the accuracy of the process input / output device 10 can be presented to the worker in detail. it can.

[Second Embodiment]
The process input / output device diagnosis system according to the second embodiment differs from the first embodiment in that the diagnosis device 30 considers the signal reading cycle between the reference signal reader 20 and the process input / output device 10.

  FIG. 5 is a block diagram showing the configuration of the process input / output device diagnosis system of the second embodiment.

  The process input / output device diagnosis system of the second embodiment further includes a time synchronization device 5.

  The time synchronizer 5 outputs time information representing the time to the process input / output device 10 and the diagnostic device 30. The time synchronization device 5 may be provided outside or inside the process input / output control device 1.

  The reference signal reader 20 is commercially available, for example, and has a different period for reading signals from the process input / output device 10. The signal reading cycle of the reference signal reader 20 is the first cycle Ta. The signal input / output period of the process input / output device 10 is a second period Tb shorter than the first period Ta.

  FIG. 6 is a diagram illustrating the execution time of the reference signal reader 20 and the signal delay time due to wiring, and the execution time of the process input / output device 10 and the signal delay time due to wiring.

  A time obtained by adding the execution time T11 of the reference signal reader 20 and the signal delay time T12 from the reference signal reader 20 to the diagnostic device 30 is defined as a first delay time T10 (T11 + T12 = T10). Further, a time obtained by adding the execution time T21 of the process input / output device 10 and the signal delay time T22 due to the wiring from the process input / output device 10 to the diagnosis device 30 is defined as a second delay time T20 (T21 + T22 = T20). In this case, the process input / output device 10, the reference signal reader 20, and the diagnostic device 30 are configured so that the first delay time T10 matches the second delay time T20 (T10 = T20). 1 is provided. Thereby, the delay due to execution time and wiring can be offset.

  FIG. 7 is a flowchart showing the operation of the process input / output device diagnosis system of the second embodiment. FIG. 8 is a diagram illustrating a signal reading cycle between the reference signal reader 20 and the process input / output device 10.

  The acquisition unit 31 of the diagnostic device 30 outputs a read request to the process input / output device 10 and the reference signal reader 20 (steps S1 and S2).

  The reference signal reader 20 reads an analog signal from the plant equipment 2 and outputs the analog signal to the diagnostic device 30 every first cycle Ta (step S21-YES) in response to the read request (step S3). .

  In response to the read request, the process input unit 11 of the process input / output device 10 reads the analog signal from the plant equipment 2 every second period Tb (step S22—YES) (step S4). At this time, the A / D converter 12 converts the analog value represented by the analog signal into a digital value by A / D conversion (step S5). The process output unit 13 outputs a process input / output signal including a digital signal representing a digital value and first time information which is time information output from the time synchronization device 5 to the diagnosis device 30 and the plant monitoring device 3 ( Step S23).

  The acquisition unit 31 of the diagnostic device 30 receives an analog signal from the reference signal reader 20 (step S7), and receives a digital signal from the process input / output device 10 (step S8). When the acquisition unit 31 receives an analog signal from the reference signal reader 20, the acquisition unit 31 generates a reference signal including the analog signal and second time information that is time information output from the time synchronization apparatus 5 (step S24). .

  Here, the time indicated by the second time information of the reference signal matches the time indicated by the first time information of the process input / output signal within a predetermined time (step S25—YES). For example, the predetermined time is a time representing the least common multiple of the first period Ta and the second period Tb. As shown in FIG. 8, when the first period Ta is 150 ms and the second period Tb is 20 ms, the time representing the least common multiple is 300 ms. For this reason, the predetermined time is 300 ms.

  In this case, the accuracy determination unit 32 of the diagnostic device 30 calculates a reference digital value from the analog value represented by the analog signal (step S9). Next, the accuracy determination unit 32 calculates an error “γ [%]” between the digital value represented by the digital signal and the reference digital value (step S10).

  Next, the accuracy determination unit 32 determines whether or not the error “γ” is within the reference range “−α <γ <+ α” and generates a determination result. When the error “γ” is within the reference range “−α <γ <+ α”, the accuracy determination unit 32 further determines that the error “γ” is within the prediction range information “−α + β <γ <+ α−β”. Is determined to generate a determination result (step S11).

  The output control unit 33 of the diagnostic device 30 outputs diagnostic information to the output device 34 (step S12). When the output device 34 is a display device, the output control unit 33 displays the contents of the diagnostic information on the display device in character notation.

  On the other hand, when the time indicated by the second time information of the reference signal and the time indicated by the first time information of the process input / output signal do not match within a predetermined time (step S25-NO), the diagnostic device 30 proceeds to the retransmission process. (Step S30).

  FIG. 9 is a flowchart showing details of the retransmission processing (step S30) of FIG.

  When the discrepancy between the time indicated by the second time information of the reference signal and the time indicated by the first time information of the process input / output signal is not consecutive a predetermined number of times (N times; N is an integer of 2 or more) (step S31-NO) ) Outputs the reading request to the process input / output device 10 (step S32), and when the sleep time has elapsed (step S33-YES), the acquisition unit 31 of the diagnostic device 30 sends the reading request to the reference signal reader 20. (Step S34). The sleep time is shorter than a predetermined time and is a time for shifting the timing of outputting a read request. Thus, the acquisition unit 31 outputs a reading request again. The sleep time varies each time the acquisition unit 31 outputs a reading request.

  At this time, the reference signal reader 20 reads the analog signal from the plant device 2 and outputs the analog signal to the diagnostic device 30 at every first period Ta (step S21-YES) in response to the reading request. (Step S3).

  In response to the read request, the process input unit 11 of the process input / output device 10 reads the analog signal from the plant equipment 2 every second period Tb (step S22—YES) (step S4). The A / D converter 12 converts the analog value represented by the analog signal into a digital value by A / D conversion (step S5). The process output unit 13 outputs a process input / output signal including a digital signal representing a digital value and first time information which is time information output from the time synchronization device 5 to the diagnosis device 30 and the plant monitoring device 3 ( Step S23).

  Thus, the acquisition unit 31 of the diagnostic device 30 receives the analog signal and the process input / output signal again (steps S7 and S8), and the second time information that is the time information output from the analog signal and the time synchronization device 5 Is generated (step S24).

  Here, when the time represented by the second time information of the reference signal matches the time represented by the first time information of the process input / output signal (step S25—YES), the accuracy determination unit 32 of the diagnostic device 30 performs the analog determination. A reference digital value is calculated from the analog value represented by the signal, an error “γ [%]” between the digital value represented by the digital signal and the reference digital value is calculated, and a determination result is generated (steps S9 to S11). The output control unit 33 of the diagnostic device 30 outputs diagnostic information including the determination result to the output device 34 (step S12).

  On the other hand, when the time indicated by the second time information of the reference signal and the time indicated by the first time information of the process input / output signal do not coincide with each other a predetermined number of times (N times) (step S31—YES), the diagnostic device 30 The output controller 33 outputs synchronization abnormality information indicating that the time cannot be synchronized to the output device 34 (step S35). When the output device 34 is a display device, the output control unit 33 displays the content of the synchronization abnormality information on the display device in text.

  As shown in FIG. 10, step S32 and step S34 may be interchanged. That is, the acquisition unit 31 of the diagnostic device 30 outputs a reading request to the reference signal reader 20 (step S34), and when the sleep time has elapsed (step S33-YES), the reading request is sent to the process input / output device 10. You may output (step S32).

  As described above, according to the present embodiment, the diagnostic device 30 considers the signal reading cycle between the reference signal reader 20 and the process input / output device 10, thereby causing an error “γ” with respect to the first embodiment. The accuracy of calculation and determination results can be improved.

[Third Embodiment]
The process input / output device diagnosis system according to the third embodiment differs from the second embodiment in that the diagnosis device 30 performs a predictive diagnosis based on a standard deviation value using a past determination result.

  FIG. 11 is a block diagram illustrating a configuration of a process input / output device diagnosis system according to the third embodiment.

  The diagnosis device 30 further includes a diagnosis result database 35, a predictive diagnosis unit 36, and a writing unit 37.

  The diagnosis result database 35 stores past determination results as needed, and further stores the storage date and time when the past determination results are stored.

  FIG. 12 is a flowchart showing the operation of the process input / output device diagnosis system of the third embodiment.

  The predictive diagnosis unit 36 of the diagnostic device 30 performs a predictive diagnosis process (step S40) after step S11.

  FIG. 13 is a flowchart showing the predictive diagnosis process (step S40) of FIG.

  The predictive diagnosis unit 36 of the diagnostic device 30 calculates a standard deviation value “α1” between the past determination result stored in the diagnosis result database 35 and the determination result generated by the accuracy determination unit 32 (step S41). The prediction diagnosis unit 36 generates a prediction diagnosis result indicating whether or not the standard deviation value “α1” exceeds a preset value “α2” (step S42).

  The writing unit 37 of the diagnostic device 30 stores the determination result and date and time generated by the accuracy determination unit 32 in the diagnosis result database 35 as a past determination result and a storage date and time, respectively (step S43).

  The output control unit 33 of the diagnostic device 30 outputs diagnostic information to the output device 34 (step S12). The diagnosis information further includes a predicted diagnosis result. When the output device 34 is a display device, the output control unit 33 displays the contents of the diagnostic information on the display device in character notation.

  As described above, according to the present embodiment, the diagnosis device 30 performs the predictive diagnosis based on the standard deviation value using the past determination result, thereby realizing the effects of the first and second embodiments and the plant equipment. It is possible to predict the failure time of the process input / output device 10 when 2 is operated for a long time.

[Fourth Embodiment]
The process input / output device diagnosis system according to the fourth embodiment differs from the third embodiment in the format in which the diagnosis device 30 outputs diagnosis information.

  The output device 34 is at least one of a display device, a printing device, and an alarm device that outputs sound.

  FIG. 14 is a flowchart showing the operation of the process input / output device diagnosis system of the fourth embodiment.

  The output control unit 33 of the diagnostic device 30 performs the output process (step S50) after the predictive diagnosis process (step S40).

  FIG. 15 is a flowchart showing the output process (step S50) of FIG. FIG. 16 is a diagram illustrating an example of special symbols given to diagnostic information.

  When the output device 34 is a display device (YES in step S51), the output control unit 33 of the diagnostic device 30 displays the contents of the diagnostic information in the character notation on the display device (step S52). Here, when the determination result generated by the accuracy determination unit 32 indicates that the error “γ” is not within the reference range “−α <γ <+ α”, the output control unit 33 includes the diagnosis information. The result abnormality information indicating that the error “γ” is not within the reference range “−α <γ <+ α” is further described with respect to the character notation of the included determination result. For example, the result abnormality information includes a special symbol such as “* (asterisk)”, and is given near the character notation of the determination result.

  Next, when the output device 34 is a printing device (YES in step S53), the output control unit 33 prints the contents of the diagnostic information in the character notation on the printing device (step S54). Here, when the determination result generated by the accuracy determination unit 32 indicates that the error “γ” is not within the reference range “−α <γ <+ α”, the output control unit 33 includes the diagnosis information. The result abnormality information “*” is further described with respect to the character notation of the included determination result.

  Next, when the output device 34 is an alarm device (step S55-YES), the output control unit 33 outputs the content of the diagnostic information as a voice from the alarm device (step S56).

  Thus, according to the present embodiment, the format in which the diagnostic device 30 outputs diagnostic information is versatile, and when the contents of the diagnostic information are written in text, the result abnormality information “*” is further written. In addition to realizing the effects of the first to third embodiments, convenience is improved.

[Fifth Embodiment]
The process input / output device diagnosis system according to the fifth embodiment differs from the fourth embodiment in that the diagnosis device 30 feeds back a correction value corresponding to an error “γ” with respect to a digital value to the process input / output device 10.

  FIG. 17 is a block diagram illustrating a configuration of a process input / output device diagnosis system according to the fifth embodiment.

  The diagnostic device 30 further includes a correction instruction unit 38.

  The process input / output device 10 further includes an automatic correction unit 14.

  FIG. 18 is a flowchart showing the operation of the process input / output device diagnosis system of the fifth embodiment.

  After step S11, the correction instruction unit 38 outputs a correction value corresponding to the error “γ” with respect to the digital value to the process input / output device 10 (step S61). At this time, the writing unit 37 stores the determination result, date / time, and correction value generated by the accuracy determination unit 32 in the diagnosis result database 35 as the past determination result, storage date / time, and past correction value, respectively.

  In response to the read request, the process input unit 11 of the process input / output device 10 reads the analog signal from the plant equipment 2 every second period Tb (step S22—YES) (step S4). At this time, the A / D converter 12 converts the analog value represented by the analog signal into a digital value by A / D conversion (step S5). The automatic correction unit 14 corrects the digital value based on the correction value output from the correction instruction unit 38 of the diagnostic device 30 (step S62). The process output unit 13 outputs a process input / output signal including a digital signal representing a digital value and first time information which is time information output from the time synchronization device 5 to the diagnosis device 30 and the plant monitoring device 3 ( Step S23). Thereafter, step S8 and subsequent steps are performed.

  Now, assume that the analog value represented by the analog signal from the reference signal reader 20 is 2 [V], and the digital value represented by the digital signal from the process input / output device 10 is 1025. According to the linear characteristics shown in FIG. 19, when the analog value is 2 [V], the reference digital value is 1000. Therefore, the error “γ” becomes 2.5% by {(1025−1000) ÷ 1000 × 100}. Here, when “α” is set to “3” and “β” is set to “1”, the worker has the error “γ” within the reference range “−α <γ <+ α”. Even in this case, when the error “γ” is in “+ α−β ≦ γ <+ α”, it can be confirmed that the deviation is close to the limit. Further, the diagnostic device 30 feeds back “−2.5 [%]” as a correction value for the error “γ” to the process input / output device 10, and the process input / output device 10 returns the correction value “−2.5 [%]” The digital value is corrected based on “”.

  Thus, according to the present embodiment, the diagnostic device 30 feeds back the correction value corresponding to the error “γ” with respect to the digital value to the process input / output device 10, thereby realizing the effects of the first to fourth embodiments. Moreover, the soundness of the process input / output device 10 during the operation of the plant equipment 2 is further improved. This embodiment is effective when the error “γ” is close to a deviation when the accuracy determination unit 32 generates a determination result. Furthermore, this is particularly effective when the error “γ” deviates.

[Other Embodiments]
As mentioned above, although some embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, modifications, and features of the embodiments can be combined without departing from the spirit of the invention. . These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

DESCRIPTION OF SYMBOLS 1 ... Process input / output control apparatus 2 ... Plant equipment 3 ... Plant monitoring apparatus 4 ... Process input distributor 5 ... Time synchronizer 10 ... Process input / output apparatus 11 ... Process input part 12 ... A / D conversion part 13 ... Process output part DESCRIPTION OF SYMBOLS 14 ... Automatic correction | amendment part 20 ... Reference signal reader 30 ... Diagnosis apparatus 31 ... Acquisition part 32 ... Accuracy determination part 33 ... Output control part 34 ... Output device 35 ... Diagnosis result database 36 ... Prediction diagnosis part 37 ... Writing part 38 ... Correction instruction section

Claims (14)

Plant equipment that outputs an analog signal representing an analog value;
A process input / output control device connected to the plant equipment, comprising a reference signal reader, a process input / output device, and a diagnostic device;
Comprising
The reference signal reader reads the analog signal from the plant equipment in response to a read request, and outputs the analog signal.
The process input / output device includes:
In response to the read request, a process input unit that reads the analog signal from the plant equipment,
An A / D converter that converts the analog value represented by the analog signal into a digital value by analog / digital (A / D) conversion;
A process output unit for outputting a digital signal representing the digital value to the diagnostic device;
Comprising
The diagnostic device comprises:
An output unit that outputs the read request to the process input / output device and the reference signal reader, receives the analog signal from the reference signal reader, and receives the digital signal from the process input / output device;
Calculating a reference digital value from the analog value represented by the analog signal, calculating an error between the digital value represented by the digital signal and the reference digital value, and generating a determination result;
An output control unit that outputs diagnostic information including the error, the determination result, and determination criterion information to an output device;
Comprising
The determination result includes reference range information indicating that the error is within a reference range from a preset lower limit value to a preset upper limit value, and an upper limit indicating that the error is greater than or equal to the upper limit value. Represents any of deviation information and lower limit deviation information indicating that the error is not more than the lower limit value,
The determination criterion information of the diagnostic information includes the lower limit deviation information, the reference range information, and the upper limit deviation information.
Process input / output device diagnosis system characterized by the above. The accuracy determination unit further determines whether or not the error is within a prediction reference range from a predicted warning lower limit value larger than the lower limit value to a predicted warning upper limit value smaller than the upper limit value. Generate a judgment result,
When the determination result represents the reference range information, the reference range information is:
Prediction range information indicating that the error is larger than the predicted warning lower limit value and smaller than the predicted warning upper limit value;
Upper limit deviation information within prediction range indicating that the error is equal to or greater than the predicted warning upper limit value and smaller than the upper limit value;
Prediction range lower limit deviation information indicating that the error is larger than the lower limit value and less than or equal to the predicted warning lower limit value;
Represents one of the following:
The determination criterion information of the diagnosis information further includes the prediction range lower limit deviation information, the prediction range information, and the prediction range upper limit deviation information.
The process input / output device diagnosis system according to claim 1. The diagnostic information further includes the digital signal, the analog signal, and the reference digital value.
The process input / output device diagnosis system according to claim 1 or 2, A time synchronization device for outputting time information representing time to the process input / output device and the diagnostic device;
Further comprising
The reference signal reader has a different period of reading a signal to the process input / output device,
The reference signal reader reads the analog signal from the plant equipment and outputs the analog signal to the diagnostic device every first cycle in response to the reading request,
The process input unit reads the analog signal from the plant equipment every second period in response to the reading request,
The A / D conversion unit converts the analog value represented by the analog signal into the digital value by A / D conversion,
The process output unit outputs a process input / output signal including the digital signal representing the digital value and first time information which is the time information output from the time synchronization device to the diagnosis device,
The acquisition unit of the diagnostic device includes:
Outputting the read request to the process input / output device and the reference signal reader; receiving the analog signal from the reference signal reader; receiving the process input / output signal from the process input / output device;
When the analog signal is received from the reference signal reader, a reference signal including the analog signal and second time information that is the time information output from the time synchronization device is generated,
When the time represented by the second time information of the reference signal matches the time represented by the first time information of the process input / output signal within a predetermined time,
The accuracy determination unit of the diagnostic device calculates the reference digital value and the error to generate the determination result;
The process input / output device diagnosis system according to claim 1, wherein the process input / output device diagnosis system is provided. The predetermined time is a time representing a least common multiple of the first period and the second period.
The process input / output device diagnosis system according to claim 4. When the time represented by the second time information of the reference signal and the time represented by the first time information of the process input / output signal do not match within the predetermined time,
The acquisition unit of the diagnostic device outputs the read request to one of the process input / output device and the reference signal reader, and is shorter than the predetermined time and for shifting the timing of outputting the read request When the sleep time has elapsed, the read request is output to the other of the process input / output device and the reference signal reader.
6. The process input / output device diagnosis system according to claim 4 or 5, wherein: When the time represented by the second time information of the reference signal and the time represented by the first time information of the process input / output signal do not match within the predetermined time,
The acquisition unit of the diagnostic device outputs the read request again to receive the analog signal and the process input / output signal,
When the time represented by the second time information of the reference signal and the time represented by the first time information of the process input / output signal do not coincide with each other a predetermined number of times,
The output control unit of the diagnostic device outputs synchronization abnormality information indicating that time synchronization cannot be performed to the output device.
7. The process input / output device diagnosis system according to claim 4, wherein the process input / output device diagnosis system is any one of claims 4 to 6. The time obtained by adding the execution time of the reference signal reader and the delay time of the signal due to wiring from the reference signal reader to the diagnostic device is defined as a first delay time,
When the time obtained by adding the execution time of the process input / output device and the signal delay time due to wiring from the process input / output device to the diagnostic device is the second delay time,
The process input / output device, the reference signal reader, and the diagnostic device are provided such that the first delay time and the second delay time coincide with each other.
8. The process input / output device diagnosis system according to claim 4, wherein the process input / output device diagnosis system according to claim 4 is used. The diagnostic device comprises:
A diagnostic result database in which past judgment results are stored as needed;
A standard deviation value between the past determination result stored in the diagnosis result database and the determination result generated by the accuracy determination unit is calculated, and whether or not the standard deviation value exceeds a preset value A predictive diagnosis unit that generates a predictive diagnosis result representing
A writing unit that stores the determination result generated by the accuracy determination unit in the diagnosis result database as the past determination result;
Further comprising
The diagnostic information further includes the predicted diagnostic result,
9. The process input / output device diagnosis system according to claim 1, wherein the process input / output device diagnosis system is any one of claims 1 to 8. The output device is at least one of a display device, a printing device, and an alarm device that outputs sound,
When the output device is the display device, the output control unit of the diagnostic device displays the contents of the diagnostic information in the character notation on the display device,
When the output device is the printing device, the output control unit of the diagnostic device prints the contents of the diagnostic information in the character notation on the printing device,
When the output device is the alarm device, the output control unit of the diagnostic device outputs the content of the diagnostic information from the alarm device as a voice,
10. The process input / output device diagnosis system according to claim 1, wherein the process input / output device diagnosis system is any one of claims 1 to 9. When the output device is the display device or the printing device, the determination result generated by the accuracy determination unit indicates that the error is not within the reference range,
The output control unit of the diagnostic device further describes result abnormality information indicating that the error is not within the reference range with respect to the determination result included in the diagnosis information.
The process input / output device diagnosis system according to claim 10. The diagnostic device further includes a correction instruction unit that outputs a correction value for the error with respect to the digital value to the process input / output device,
The process input / output device further includes an automatic correction unit,
The process input unit reads the analog signal from the plant equipment in response to the read request,
The A / D conversion unit converts the analog value represented by the analog signal into the digital value by A / D conversion,
The automatic correction unit corrects the digital value based on the correction value output from the correction instruction unit of the diagnostic device,
The process output unit outputs the digital signal representing the digital value to the diagnostic device;
12. The process input / output device diagnosis system according to claim 1, wherein the process input / output device diagnosis system is any one of claims 1 to 11. A process input / output control device connected to plant equipment that outputs an analog signal representing an analog value,
A reference signal reader, a process input / output device and a diagnostic device;
The reference signal reader reads the analog signal from the plant equipment in response to a read request, and outputs the analog signal.
The process input / output device includes:
In response to the read request, a process input unit that reads the analog signal from the plant equipment,
An A / D converter that converts the analog value represented by the analog signal into a digital value by analog / digital (A / D) conversion;
A process output unit for outputting a digital signal representing the digital value to the diagnostic device;
Comprising
The diagnostic device comprises:
An output unit that outputs the read request to the process input / output device and the reference signal reader, receives the analog signal from the reference signal reader, and receives the digital signal from the process input / output device;
Calculating a reference digital value from the analog value represented by the analog signal, calculating an error between the digital value represented by the digital signal and the reference digital value, and generating a determination result;
An output control unit that outputs diagnostic information including the error, the determination result, and determination criterion information to an output device;
Comprising
The determination result includes reference range information indicating that the error is within a reference range from a preset lower limit value to a preset upper limit value, and an upper limit indicating that the error is greater than or equal to the upper limit value. Represents any of deviation information and lower limit deviation information indicating that the error is not more than the lower limit value,
The determination criterion information of the diagnostic information includes the lower limit deviation information, the reference range information, and the upper limit deviation information.
A process input / output control device. A process input / output controller connected to a plant device that outputs an analog signal representing an analog value, and comprising a process input / output device, a reference signal reader, and a diagnostic device, diagnoses the process input / output device,
The reference signal reader reads the analog signal from the plant equipment in response to a read request, and outputs the analog signal to the diagnostic device;
The process input / output device reading the analog signal from the plant equipment in response to the read request;
The process input / output device converts the analog value represented by the analog signal into a digital value by analog / digital (A / D) conversion;
The process input / output device outputting a digital signal representing the digital value to the diagnostic device;
The diagnostic device outputs the read request to the process input / output device and the reference signal reader, receives the analog signal from the reference signal reader, and receives the digital signal from the process input / output device;
The diagnostic device calculates a reference digital value from the analog value represented by the analog signal, calculates an error between the digital value represented by the digital signal and the reference digital value, and generates a determination result;
The diagnostic device outputs diagnostic information including the error, the determination result, and determination criterion information to an output device;
Comprising
The determination result includes reference range information indicating that the error is within a reference range from a preset lower limit value to a preset upper limit value, and an upper limit indicating that the error is greater than or equal to the upper limit value. Represents any of deviation information and lower limit deviation information indicating that the error is not more than the lower limit value,
The determination criterion information of the diagnostic information includes the lower limit deviation information, the reference range information, and the upper limit deviation information.
And a process input / output device diagnosis method.

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