JP2020141340A - Diagnostic device, diagnostic system, and diagnostic method - Google Patents

Abstract

To solve a problem in which, in the field of diagnosing a production system and the like, there has been a demand for a diagnostic device in which power consumption is suppressed and diagnostic information with a large amount of data can be transmitted to an administrator without hindrance even when a plurality of units are arranged close to each other.SOLUTION: In a diagnostic system that diagnoses a production device, a diagnostic device 103 includes a first wireless communication unit (LPWA), a second wireless communication unit (NFC) having a wider communication band than the first wireless communication unit (LPWA), and a control unit 200 that controls an operation mode. The diagnostic device can execute: an autonomous diagnostic mode in which a measurement signal related to the state of the device to be diagnosed is acquired, and simple diagnostic information generated by processing the measurement signal is transmitted from an LPWA; and a monitor mode in which a measurement signal related to the state of the device to be diagnosed is acquired, and detailed diagnostic information generated by performing a process different from that in the autonomous diagnostic mode is transmitted from an NFC to a portable terminal device when the NFC establishes wireless communication with the portable terminal device.SELECTED DRAWING: Figure 2

Description

The present invention relates to a diagnostic device and a diagnostic method for diagnosing a device or facility using a sensor in a facility equipped with various devices or equipment, such as a production line of a chemical plant or a factory.

In a facility equipped with various devices and equipment such as production equipment, even if an abnormality occurs in the equipment during operation, the administrator will immediately make an abnormality as long as there is no direct problem with the intended operation. It was difficult to recognize. At the stage when the administrator recognizes the abnormality due to a hindrance to the intended operation, the defective part has been worn or damaged to a considerable extent, so the cost required for repairing the device and the suspension period are large. I have.

Therefore, preventive maintenance such as inspection, repair, and replacement of parts has come to be carried out at regular intervals, and it has become possible to avoid a situation in which an abnormality of the device progresses significantly without being discovered. However, if inspections, repairs, parts replacement, etc. are carried out on a regular basis, a considerable amount of man-hours will be required, which will increase the maintenance cost of the equipment, and the operation of the facility will have to be stopped during the maintenance work. There was a problem that the rate dropped.

In response to such problems, in recent years, diagnostic devices equipped with sensors and the like are used to monitor devices and equipment in operation, diagnose the presence or absence of abnormalities due to deterioration of parts, etc., and if necessary, Predictive maintenance is being attempted for replacement and repair. Predictive maintenance can be said to be an attempt to save man-hours and excessive parts replacement required to carry out regular inspections.

Although it is not in the field of production equipment, Patent Document 1 states in Patent Document 1 whether or not a sensor is used to determine whether or not the output and rotation speed of a mechanical device are stably obtained, and the presence or absence of an abnormality is diagnosed. The device is disclosed. In this device, when it is determined that the rotation speed is not stable, the data is reduced and transmitted to the external data storage unit for storage, and when it is determined that the rotation speed is stable. Saves data in the internal data storage section without reducing it.

JP-A-2017-219325

For example, a diagnostic device used for diagnosing a production system or the like is often installed close to each of the production devices and equipment which are components of the production system or the like. Further, a plurality of diagnostic devices may be installed in one production device or equipment. Then, in order to omit the complicated work of wiring the power line and the signal line to each diagnostic device, each diagnostic device is often equipped with a battery so that data communication with the outside is performed by wireless communication.
Therefore, a diagnostic device used for diagnosis of a production system or the like is required to have low power consumption and not to hinder wireless data communication even if a plurality of units are installed close to each other.

When the data storage method of the wind power generator disclosed in Patent Document 1 is adopted for a diagnostic device used for diagnosis of a production system or the like, the internal data storage unit does not reduce the data in normal times when no abnormality occurs. It is necessary to provide a large-capacity memory in the diagnostic device in order to store the data in the diagnostic device. Then, not only the cost of the diagnostic device increases, but also the power consumption increases, so that the operating time of the battery becomes short. Further, in Patent Document 1, a wireless data communication method when a plurality of diagnostic devices are arranged close to each other has not been studied.

Therefore, in the field of diagnosing production systems and the like, there has been a demand for a diagnostic device that can suppress power consumption and can transmit diagnostic information with a large amount of data to an administrator without hindrance even if a plurality of units are arranged close to each other. ..

The present invention includes a first wireless communication unit, a second wireless communication unit having a wider communication band than the first wireless communication unit, and a control unit that controls an operation mode, and is a device to be diagnosed. An autonomous diagnosis mode in which a measurement signal related to a state is acquired and simple diagnosis information generated by processing the measurement signal is transmitted from the first wireless communication unit, and a portable terminal device in which the second wireless communication unit transmits the simple diagnosis information. When wireless communication is established between the two, the detailed diagnostic information generated by acquiring the measurement signal related to the state of the device to be diagnosed and performing a process different from the autonomous diagnostic mode is used in the second It is a diagnostic device characterized in that it can execute a monitor mode of transmitting from a wireless communication unit to the portable terminal device.

Further, in the present invention, the diagnostic device takes a measurement signal from a sensor that measures the state of the device to be diagnosed, performs the first signal processing, and performs the first signal processing, and the diagnosis target is based on the result of the first signal processing. A determination process for determining the presence or absence of an abnormality in the device, and a determination result transmission process for transmitting information related to the result of the determination process from the first wireless communication unit are executed, and the determination process is the target of the diagnosis. When it is determined that there is an abnormality in the device, the measurement signal is further taken in from the sensor, the second signal processing having a larger calculation amount than the first signal processing is performed, and the second signal processing is performed. A detailed diagnostic storage process for storing the result of the above is executed, and after the detailed diagnostic storage process, the second wireless communication unit having a communication band larger than that of the first wireless communication unit and the portable terminal device When communication is established between them, the detailed diagnosis result transmission process of transmitting the result of the second signal processing stored in the storage unit from the second wireless communication unit to the portable terminal device is executed. It is a diagnostic method characterized by doing.

The present invention provides a diagnostic device in which power consumption is suppressed and diagnostic information having a large amount of data can be transmitted to an administrator without hindrance even when a plurality of units are arranged close to each other.

The schematic diagram of the system example provided with the diagnostic apparatus of embodiment. The schematic block diagram of the diagnostic apparatus of embodiment. The figure which shows the state transition of the diagnostic apparatus of embodiment. The operation flowchart of the diagnostic apparatus of embodiment. The schematic diagram of the system provided with the diagnostic apparatus of Example 1. FIG. The schematic diagram of the system provided with the diagnostic apparatus of Example 2. A time chart showing changes in the operating state of the diagnostic apparatus of the embodiment. The figure which illustrates the display screen of the portable terminal which can be connected to the diagnostic apparatus of an Example.

The diagnostic apparatus, diagnostic system, and diagnostic method according to the embodiment of the present invention will be described with reference to the drawings. In the drawings referred to in the following embodiments and examples, unless otherwise specified, the members and the like having the same reference number shall have the same function.

[Embodiment]
FIG. 1 is a diagram schematically showing a configuration example of a diagnostic system for diagnosing a production apparatus using the diagnostic apparatus of the embodiment. A sensor 102 used for diagnosing the production device 101 is arranged in the production device 101, and the diagnostic device 103 of the embodiment is connected to the sensor 102.

The sensor 102 is a sensor capable of outputting the measured physical quantity as an analog or digital signal, such as a vibration sensor, an acceleration sensor, a pressure sensor, an optical sensor, a torque sensor, and a temperature sensor. Depending on the type and characteristics of the production device 101, an appropriate type of sensor 102 is selected for measuring the physical quantity required for diagnosis, and is arranged at an appropriate position of the production device 101. The sensor 102 may be a sensor pre-installed in the production device 101, or may be a sensor attached to the diagnostic device 103. In FIG. 1, one sensor 102 is connected to the diagnostic device 103, but the present invention is not limited to this example, and the type and number of sensors required for diagnosis are arranged in various places in the production device 101 to the diagnostic device 103. Just connect.

Further, for convenience of illustration, although only one diagnostic device 103 is arranged in the production device 101 in FIG. 1, a plurality of diagnostic devices may be arranged in one production device. The sensor 102 may receive power necessary for operation from a power source such as the production device 101, and in that case, the sensor 102 may be constantly operated. Further, when the sensor 102 receives the power supply from the diagnostic device 103, it is preferable to operate the sensor 102 only when performing the diagnosis in order to save the power consumption of the battery of the diagnostic device 103.

By the way, when the diagnostic device for diagnosing the production equipment or the like detects the occurrence of an abnormality, it is necessary to first notify the administrator from the diagnostic device that the occurrence of the abnormality has been detected. The administrator who receives the notification and recognizes the occurrence of the abnormality will try to obtain more detailed diagnostic information regarding the condition and cause of the abnormality. If we try to always provide detailed and highly accurate diagnostic information, the amount of data handled by the diagnostic device will constantly increase, and the data processing load and memory usage will increase, resulting in increased power consumption in the diagnostic device. growing. In addition, since the amount of information when transmitting detailed diagnostic information to the administrator increases, the communication band of wireless communication is squeezed in the area where a plurality of diagnostic devices are arranged.

On the other hand, in the case of a production system or a manufacturing plant facility, unlike wind power generation facilities installed in remote areas, a manager at a management center or the like can move to the production device or facility in a short time. There are many. The manager who is in the management center and recognizes the occurrence of an abnormality in the production equipment, etc., moves to the site where the production equipment can be inspected, rather than waiting for a long time until the detailed diagnostic information is received wirelessly at the management center. Then you will want to get detailed diagnostic information on the spot.

Therefore, the diagnostic device of the present embodiment notifies the manager in the management center or the like of the occurrence of an abnormality in the production device or the like, and when the manager is in the vicinity of the production device, the diagnostic information having a large amount of data is not hindered. It is capable of transmission and has a feature that power consumption is suppressed.
Specifically, the diagnostic device 103 of the embodiment includes a long-distance wireless communication means 106 as a first wireless communication unit and a short-range wireless communication means 105 as a second wireless communication unit. The long-distance wireless communication means 106 is a communication means capable of communicating over a long distance although the communication band is relatively narrow, such as LPWA (Low Power Wide Area). Further, the short-range wireless communication means 105 is a communication means such as NFC (Near Field Communication) which has a wider communication band but a shorter communication distance than the long-range wireless communication means 106.

The diagnostic device 103 is installed within a distance capable of communicating with the gateway 107 by the long-distance wireless communication means 106. In other words, at least one or more gateways 107 are installed within a range in which radio waves from the long-distance wireless communication means 106 of the diagnostic device 103 can be received. The external network 108 connected to the gateway 107 may be, for example, a dedicated network in a factory or the Internet.

As will be described later, the long-distance wireless communication means 106 transmits simple diagnostic information with a small amount of information from the diagnostic device 103, but the simple diagnostic information received by the gateway 107 is stored in the database 109 connected to the network 108. Will be done. The simple diagnostic information stored in the database 109 can be confirmed by the manager of the production facility using, for example, a computer 110 connected to the network 108. Alternatively, when the computer 110 automatically accesses the simple diagnostic information and determines that an abnormality has occurred in the production device 101, the computer 110 sends an alert to the administrator by using a notification means such as voice or e-mail transmission. You may.

The diagnostic device 103 establishes short-range wireless communication with the portable terminal device 104 when the administrator brings the portable terminal device 104 close to the portable terminal device 104 within a distance that can be communicated by the short-range wireless communication means 105. Can communicate with each other. As will be described later, the diagnostic device 103 can transmit detailed diagnostic information having a large amount of information to the portable terminal device 104 whose communication has been established by the short-range wireless communication means 105.

The portable terminal device 104 is a terminal device that can be carried by an administrator, and includes a short-range wireless communication means, a computer, a memory, a display unit, a battery, and the like. A display unit and memory large enough for the portable terminal device 104 so that the administrator can acquire detailed diagnostic information and easily check the contents at the site such as a production facility where an abnormality has occurred. It is desirable to equip. Further, in order to enable power supply from the portable terminal device 104 to the diagnostic device 103, it is desirable that the portable terminal device 104 is provided with a battery having a sufficient size or a connector to an external power source.

Next, FIG. 2 shows a schematic block diagram of the diagnostic apparatus 103. The diagnostic device 103 includes a battery 210 as a power source. Electric power may be supplied from a commercial power source or a power source in the production apparatus instead of the battery 210 or in combination with the battery 210. Further, the diagnostic device 103 includes a long-distance wireless communication means 106 and a short-range wireless communication means 105. The control unit 200 is a control circuit that controls the operation of each unit of the diagnostic device 103, and can be configured by a computer or hardware such as an ASIC. The timer trigger 206 is a functional block that generates a timing for executing the autonomous diagnosis, and generates a trigger signal for starting the autonomous diagnosis at a fixed time or at regular time intervals with reference to the clock 211. By executing the diagnosis of the production apparatus 101 in a timely manner by using the timer trigger 206, it is possible to carry out predictive maintenance while suppressing the power consumption of the battery 210.

One or more sensors 201 installed in the production device 101 are connected to the diagnostic device 103. The diagnostic device 103 includes an AD converter 204, and when the output signal of the sensor 201 is an analog signal, it is converted into a digital signal by the AD converter 204 and input to the signal processor 205. The signal processor 205 performs digital signal processing necessary for diagnosis, and outputs an evaluation target value in the case of simple measurement. As will be described later, the signal processor 205 shall perform different signal processing between the first signal processing for simple measurement and the second signal processing for detailed measurement. .. If the output signal of the sensor 201 has already been digitized, it is directly input to the signal processor 205 without passing through the AD converter 204, and the same digital signal processing is performed.

The evaluation target value output by the signal processor 205 is input to the comparator 203. A predetermined threshold value 209 for determining whether the production device 101 is normal or abnormal is stored in the memory of the diagnostic device 103, and the comparator 203 compares the input evaluation target value with the threshold value 209. ..
The output of the comparator 203 is the result of determining whether or not there is an abnormality in the production device 101, and the determination result is the simple diagnostic information with a small amount of information regardless of the presence or absence of the abnormality from the long-distance wireless communication means 106 to the gateway 107. Will be sent to. Details will be described later, but if the determination result by the comparator 203 is abnormal in the production device 101, the number of samplings of the sensor 201 is increased, and the signal processing necessary for making a detailed diagnosis is performed by the signal processor 205. Do. The result of this signal processing is stored in the internal storage device 208 as detailed diagnostic information having a large amount of information. The detailed diagnostic information with a large amount of information stored in the internal storage device 208 is a short distance when the administrator brings the portable terminal device 104 close to the portable terminal device 104 within a communication range by the short range wireless communication means 105 and communication is established. It is transmitted to the portable terminal device 104 by the wireless communication means 105.

(Operation of diagnostic device / diagnostic method)
Hereinafter, the operation and the diagnosis method of the diagnostic apparatus 103 will be described with reference to the state transition diagram of FIG. 3 and the operation flowchart of FIG.
FIG. 3 is a state transition diagram for explaining the transition of the operation mode executed by the diagnostic apparatus 103. The diagnostic device 103 can execute at least the autonomous diagnostic mode M1, the standby mode M2, the monitor mode M3, and the monitor end confirmation mode M4 under the control of the control unit 200.

When the diagnostic device 103 starts operating in step S0 of FIG. 4, it is confirmed in step S1 whether a communication connection has been established with the portable terminal device 104 via the short-range wireless communication means 105. The short-range wireless communication means 105 is a communication means having a wide communication band but a short communication distance.
When the short-range wireless communication connection with the portable terminal device 104 is established (step S1: YES in FIG. 4), the monitor mode M3 of FIG. 3 is executed. The operation contents of the monitor mode M3 will be described later.

When the short-range wireless communication connection with the portable terminal device 104 is not established (step S1: NO in FIG. 4), the monitor end confirmation mode M4 in FIG. 3 is executed in step S14. In this mode, the administrator terminates the communication, perhaps because the short-range wireless communication connection is temporarily interrupted due to, for example, the administrator inadvertently moving the portable terminal device 104, although communication is originally in progress. It is confirmed whether the portable terminal device 104 is in an isolated state in order to do so. In other words, in step S14, the administrator may have terminated the short-range wireless communication connection in order to complete the monitor mode M3, or the short-range wireless communication connection is temporarily interrupted even though the monitor mode M3 is desired to be continued. Determine if it has happened.

Specifically, for example, when the period during which the connection is disconnected is measured and the short-range wireless communication connection is restored within a predetermined period (step S14: NO in FIG. 4), it is said that the interruption was temporary. to decide. If the short-range wireless communication connection is not restored even after a predetermined period of time has passed (step S14: YES in FIG. 4), the administrator has terminated the short-range wireless communication in order to complete the monitor mode M3. Judge.
The diagnostic device 103 returns to the monitor mode M3 when it determines that the interruption is temporary, and shifts to the standby mode M2 when it determines that the short-range wireless communication has ended.

For convenience of explanation, the operation of the diagnostic device 103 in the standby mode M2 will be described first. In the standby mode M2, the control unit 200 waits for the timer trigger 206 to generate a trigger signal for starting the autonomous diagnosis while suppressing the power supply to the unused portion during the standby mode (NO in step S2, NO loop in step S1 and YES loop in step S14). The consumption of the battery 210 is suppressed by stopping the clock of the MPU (not shown) or changing the clock to a low frequency, or by cutting off the power supply to parts that are not used in the standby mode such as the AD converter 204 and the signal processor 205. To do.

When the diagnosis interval or the diagnosis time coincides with the predetermined diagnosis, the timer trigger 206 generates a trigger signal to start the autonomous diagnosis (step S2: YES). Upon generation of the trigger signal, the state of the diagnostic device shifts from the standby mode M2 in FIG. 3 to the autonomous diagnostic mode M1.
When the mode shifts to the autonomous diagnosis mode M1, the control unit 200 controls the power feeding unit and supplies power to the AD converter 204, the signal processor 205, and the like, which are circuits necessary for executing the autonomous diagnosis mode. Further, when the clock of the MPU (not shown) is stopped, it is activated, and when it is already activated, the frequency is increased to enable the autonomous diagnosis mode to be executed.

Then, the diagnostic device 103 performs a simple measurement in step S3. The diagnostic device 103 acquires a necessary and sufficient number of measurement signals from the sensor 201 in order to diagnose whether the production device 101 is normal or abnormal.
The measurement signal acquired from the sensor 201 is digitized by the AD converter 204 and then arithmetically processed by the signal processor 205, and is a simple evaluation target value (measurement result) such as an effective value, an average value, a maximum value, and a minimum value. Is required. The arithmetic processing here is necessary and sufficient arithmetic for diagnosing whether the production apparatus 101 is normal or abnormal.

In step S4, the simple evaluation target value obtained in step S3 and the predetermined threshold value 209 corresponding to the simple evaluation target value are compared using the comparator 203, and there is no abnormality in the production apparatus 101. Is determined. This determination result and the arbitrarily selected simple evaluation target value are collectively referred to as simple diagnostic information here.
If the determination result is normal (step S4: NO), the diagnostic device 103 executes step S5N and transmits simple diagnostic information from the long-distance wireless communication means 106 toward the gateway 107. After that, the process returns to step S1.

If the determination result is abnormal (step S4: YES), the diagnostic device 103 executes step S5A and transmits simple diagnostic information from the long-distance wireless communication means 106 to the gateway 107.
Then, in step S6, detailed measurement is performed. First, the diagnostic apparatus 103 acquires a measurement signal from the sensor 201 with a sufficient number of samples and a measurement cycle necessary for diagnosing the abnormality of the production apparatus 101 in detail. The measurement signal acquired by the detailed measurement in step S6 is much larger than the measurement signal acquired by the simple measurement in step S3.

The measurement signal acquired from the sensor 201 is digitized by the AD converter 204 and then input to the signal processor 205, where arithmetic processing such as fast Fourier transform, wavelet transform, and convolution processing is performed. The arithmetic processing performed by the signal processor 205 in step S6 is much larger than the arithmetic processing performed in step S3, but is processed at high speed by a method such as increasing the frequency of the arithmetic clock. The result of the processing is useful information for identifying the location, type, degree, etc. of the abnormality occurring in the production apparatus 101, and is called detailed diagnostic information. The detailed diagnostic information obtained in step S6 has a much larger amount of information than the simple diagnostic information obtained in step S3.
In step S7, the detailed diagnostic information is stored in the internal storage device 208. After that, the process returns to step S1.

In the flow of FIG. 4, after the completion of the autonomous diagnosis mode M1, the process returns to step S1 to confirm whether the NFC communication connection is established, but another control method is also possible. For example, it may be controlled to constantly monitor whether the NFC communication connection is established, and when the connection is detected, generate an interrupt process, immediately jump to step S1, and shift to the monitor mode M3.

Next, the monitor mode M3 will be described. The monitor mode M3 is a mode for the administrator to acquire the detailed diagnostic information stored in the diagnostic device 103 and the detailed diagnostic information obtained by measuring in real time by using the portable terminal device 104.
When it is confirmed in step S1 that communication has been established with the portable terminal device 104 via the short-range wireless communication means 105 (step S1: YES in FIG. 4), the monitor of FIG. 3 The mode shifts to M3.
After shifting to the monitor mode M3, in step S8, it is confirmed whether or not the detailed diagnostic information is stored in the internal storage device 208.

If the diagnostic information is not saved (step S8: NO), the process proceeds to step S11. When the diagnostic information is saved (step S8: YES), in step S9, the saved diagnostic information is transmitted to the portable terminal device 104 by the short-range wireless communication means 105, and the process proceeds to step S11. The administrator receives the detailed diagnosis information saved in the step S7 of the autonomous diagnosis mode M1 or the detailed diagnosis information saved at a timing different from this in the portable terminal device 104, and determines the abnormality of the production device 101. Get detailed information. Since the short-range wireless communication means 105 has a wider communication band than the long-range wireless communication means 106, it is possible to transmit detailed diagnostic information having a large amount of information in a short time, and interference or interference occurs in relation to the communication means of other diagnostic devices. It does not occupy the communication band.

Then, in the process S11 or later of the monitor mode M3, the latest state of the production device 101 is monitored, and detailed diagnostic information is transmitted to the portable terminal device 104.
In step S11, a measurement item, a measurement cycle, and / or a number of samples suitable for monitoring the latest state are set. When monitoring the latest state, the same measurement item and measurement cycle as the detailed measurement in step S6 may be used, or another measurement item and measurement cycle may be used. The measurement item and the measurement cycle in the monitor mode M3 may be set in advance in the program of the diagnostic device 103, or may be set or changed by the administrator from the portable terminal device 104.

Then, in step S12, the real-time state of the production apparatus 101 is monitored. That is, the diagnostic device 103 first acquires a measurement signal of a sufficient number of samples necessary for diagnosing the latest state of the production device 101 in detail from the sensor 201. Of course, the measurement signal acquired by the detailed measurement in step S12 is much larger than the measurement signal acquired by the simple measurement in step S3. The measurement signal acquired from the sensor 201 is digitized by the AD converter 204 and then input to the signal processor 205. As the third signal processing, which requires a larger amount of calculation than the first signal processing, a fast Fourier transform and a wavelet are used. Arithmetic processing such as conversion and convolution processing is performed. As a result, real-time, that is, the latest detailed diagnostic information can be obtained.

Next, in step S13, the latest detailed diagnostic information is transmitted to the portable terminal device 104 by the short-range wireless communication means 105. Then, the process returns to step S1 and it is confirmed whether the NFC communication connection is continuously established. Here, if the connection is disconnected (step S1: NO), the mode shifts to the monitor end confirmation mode M4 in the state diagram of FIG.

That is, when the monitor end confirmation mode M4 is entered, in step S14, it is checked whether the disconnected state of NFC communication with the portable terminal device 104 continues for a predetermined time or longer. The administrator may have terminated the short-range wireless communication connection to complete the monitor operation (detailed diagnosis of the latest state of the production equipment), or the short-range wireless communication connection is temporarily interrupted even though the monitor operation is desired to continue. Determine if you have done it. If the short-range wireless communication connection is not restored even after the lapse of a predetermined period or more (step S14: YES), it is determined that the short-range wireless communication communication has ended, and the mode shifts to the standby mode M2 described above. ..

In the flow of FIG. 4, after the completion of the step S13, the process returns to the step S1 to check whether the NFC communication connection is established, but another control method is also possible. For example, while the monitor mode M3 is being executed, it is constantly monitored whether NFC communication is established, and when a disconnection of communication is detected, interrupt processing is immediately generated and the process is controlled to shift to step S14. May be good.

When the short-range wireless communication connection is restored within a predetermined period (step S14: NO), it is determined that the interruption was temporary, the monitor mode M3 is restored, and the step S15 is executed.
In step S15, among the detailed diagnosis results by measurement performed during the period when the NFC communication connection was disconnected, the information that has not yet been transmitted to the portable terminal device 104 is temporarily stored in the internal storage device 208.
Then, in step S16, real-time detailed measurement is continuously performed, and monitoring of the latest state of the production apparatus 101 is continued.
In step S17, the untransmitted detailed diagnosis result saved in step S15 and the latest detailed diagnosis result acquired in step S16 are collectively transmitted to the portable terminal device 104.

As can be seen from the above description, the diagnostic device 103 is normally in the state of the standby mode M2 in which the power consumption is suppressed, but when the timer triggers at an appropriate timing, the diagnostic device 103 shifts to the autonomous diagnostic mode M1. In the autonomous diagnosis mode M1, the presence or absence of abnormality in the production device 101 is diagnosed by a simple measurement with less energy consumption, and the simple diagnosis result (information on the presence or absence of abnormality) with a small amount of information is obtained by the long-distance wireless communication means 106. Send. Then, when an abnormality occurs, the diagnostic device 103 autonomously executes the detailed diagnosis and stores the detailed diagnosis result having a large amount of information in the internal storage device 208.

The administrator who recognizes the occurrence of an abnormality based on the transmitted simple diagnosis result sets the diagnostic device 103 in the monitor mode by bringing the portable terminal device 104 close to the diagnostic device 103 and establishing the connection of the short-range wireless communication means 105. It can be transferred to M3. In the monitor mode M3, the administrator can acquire detailed diagnostic information having a large amount of information by wideband short-range wireless communication, and can easily confirm the detailed diagnostic information on the display unit of the portable terminal device 104. In the monitor mode M3, not only the detailed diagnosis information saved in the autonomous diagnosis mode M1 is transmitted, but also the detailed diagnosis is executed in real time as the first monitor diagnosis process, and the detailed diagnosis result is transmitted by short-range wireless communication to the portable terminal. It can be transmitted to the device 104.

If the short-range wireless communication connection is disconnected while the monitor mode M3 is being executed, the mode shifts to the monitor end confirmation mode M4, and the administrator may have completed the monitor operation, or the monitor operation is temporarily continued. Determine if communication has been interrupted.

Even if no abnormality has occurred in the production device 101, if the administrator brings the portable terminal device 104 close to the diagnostic device 103 and connects to the short-range wireless communication, the diagnostic device 103 can be set to the monitor mode. It is possible to shift to M3 and perform detailed diagnosis in real time. That is, it is possible to perform the fourth signal processing, which requires a larger amount of calculation than the first signal processing, and execute the second monitor diagnosis processing.

As described above, according to the embodiment, a diagnostic device and a diagnostic method capable of transmitting diagnostic information having a large amount of data to the administrator without any trouble even if a plurality of units are arranged close to each other while suppressing power consumption. It can be realized.

(Example 1)
Hereinafter, Example 1 of the present invention will be described with reference to the drawings.
Here, a procedure in which the diagnostic device makes a diagnosis and transmits the diagnosis result will be described by taking as an example a case where an abnormality occurs in one of the two pumps installed in the production device.
FIG. 5 shows a schematic diagram of the production system of Example 1 to which the diagnostic apparatus of the present invention is applied. A pump 125 and a pump 126 are installed in the production facility 1101, and a vibration sensor 123 and a vibration sensor 124 are installed to diagnose each pump. Each vibration sensor is connected to the diagnostic device 121 and the diagnostic device 122, and monitors each pump. The diagnostic device 121 and the diagnostic device 122 transition from the standby state of the standby mode M2 to the autonomous diagnostic mode M1 once an hour by a trigger generated by the timer trigger 206, which is a trigger unit included in each diagnostic device, to simplify the pump. Make a diagnosis. In the simple diagnosis, the acceleration RMS is measured and diagnosed.

Explaining the case where the wing 128 of the pump 126 is normal, only steady normal vibration is generated during operation. The diagnostic device 122 transitions from the standby state of the standby mode M2 to the autonomous diagnosis mode M1 by the timer trigger 206 in the diagnostic device 122, and starts the diagnosis. The analog output signal of the vibration sensor 124 is taken in and digitized by the AD converter 204 in the diagnostic device 122, and the acceleration RMS value is calculated by the signal processor 205 in the diagnostic device 122. When the comparator 203 in the diagnostic device 122 compares the acceleration RMS value based on the measurement result of the vibration sensor 124 with the threshold value 209 stored in advance in the diagnostic device 122, it is diagnosed as normal in this case. ..

The simple diagnosis result of normality and the acceleration RMS value are transmitted to the gateway 107 by the long-distance radio communication means 106 of the 920 MHz band specific low power radio in the diagnosis device 122. That is, the determination result transmission process is executed. The band of the long-distance wireless communication means 106 of the 920 MHz band specific low power radio in the diagnostic apparatus 122 is, for example, about 50 kbps.

On the other hand, regarding the pump 125, it is assumed that the wings 127 are damaged and abnormal vibration starts to occur during operation. The diagnostic device 121 shifts from the standby state of the standby mode M2 to the autonomous diagnosis mode M1 by the timer trigger 206 in the diagnostic device 121, and starts the simple diagnosis. The analog output signal of the vibration sensor 123 is digitized by the AD converter 204 in the diagnostic device 121, and the value of the acceleration RMS is calculated by the signal processor 205 in the diagnostic device 121. When the comparator 203 in the diagnostic device 121 compares the acceleration RMS value based on the measurement result of the vibration sensor 123 with the threshold value 209 stored in advance in the diagnostic device 121, an abnormality is diagnosed in this case. ..

The simple diagnosis result of abnormality and the acceleration RMS value are transmitted to the gateway 107 by the long-distance wireless communication means 106 of the 920 MHz band specific low power radio in the diagnostic device 121. That is, the determination result transmission process is executed.

When an abnormality is diagnosed, the output signal of the vibration sensor 123 is digitized for detailed diagnosis, the signal processor 205 in the diagnostic device 121 performs wavelet transform with a large amount of calculation, and the data is stored in the diagnostic device 121. It is stored in the internal storage device 208 of. That is, the detailed diagnostic storage process is executed.

The administrator 129 of the production apparatus 101 confirms the simple diagnosis result stored in the database 109 via the gateway 107 and the network 108 on the computer 110. After confirming that an abnormality has occurred in the pump 125, the administrator 129 carries the portable terminal 1104 equipped with the NFC (ISO / IEC 14443 Type A) short-range wireless communication means 105 and installs the pump 125. Head to the production facility 1101. The band of the short-range wireless communication means 105 by P2P transfer is, for example, about 400 kbps. The short-range wireless communication means 105 may be switched to a communication path such as Bluetooth (registered trademark) or Wi-Fi by handover of the communication path.

The administrator 129 brings the portable terminal 1104 close to the diagnostic device 121 of the pump 125 in which the abnormality has occurred, and establishes communication with the short-range wireless communication means 105. When communication by the short-range wireless communication means is established with the portable terminal 1104, the diagnostic device 121 transitions from the standby state of the standby mode M2 to the monitor mode M3. The diagnostic device 121 transmits detailed diagnostic information such as wavelet transform stored in the internal storage device 208 when an abnormality is diagnosed to the portable terminal 1104 by using the short-range wireless communication means 105. That is, the detailed diagnosis result transmission process is executed. The detailed diagnostic information is displayed on the display screen of the portable terminal using an application (not shown) of the portable terminal 1104.

Detailed diagnostic information such as the wavelet transform result has a much larger amount of information than simple diagnostic information such as the acceleration RMS value. When the detailed diagnostic information is transmitted by the long-distance wireless communication means 106, the communication time is long because the band is limited. Further, the long communication time not only shortens the battery life of the diagnostic device 121, but also occupies the communication band during communication. In the diagnostic apparatus of the embodiment, by transmitting the detailed diagnosis result by the short-range wireless communication means 105, it is possible to transmit without occupying the band of the long-range wireless communication means 106.

A power receiving coil for wireless power supply may be provided in the diagnostic device 121, and the diagnostic device 121 may receive wireless power supply from the portable terminal 1104 while communication by the short-range wireless communication means 105 is established. .. As a result, it is possible to suppress the consumption of the battery 210 of the diagnostic device 121 while executing the monitor mode M3, which consumes a large amount of power. According to the diagnostic device and the diagnostic method of this embodiment, detailed diagnostic information having a large amount of information due to short-distance wireless communication even if the battery life of the diagnostic device is maintained for a long time and the band of long-distance wireless communication is limited. Can be transmitted without any trouble.

(Example 2)
Hereinafter, Example 2 of the present invention will be described with reference to the drawings. Here, a procedure for installing and operating the diagnostic device of the present invention will be described in order to diagnose the pressure state of the compressor in the production device.
FIG. 6 shows a schematic diagram of a production system to which the diagnostic apparatus of the second embodiment is applied. A compressor 130 is installed in the production apparatus 101. The administrator 133 of the diagnostic apparatus installs the pressure sensor 131 in the compressor so that the pressure state of the compressor can be measured, and connects the pressure sensor 131 to the diagnostic apparatus 103.

In order to confirm whether the pressure sensor 131 is correctly installed and correctly wired to the diagnostic device 103, the administrator 133 uses the portable terminal 2104 provided with the short-range wireless communication means to communicate with the short-range wireless communication means 105 of the diagnostic device 103. Move within the possible range 132. As a result, the diagnostic device 103 transitions from the standby state of the standby mode M2 to the monitor mode M3 and enters the monitoring state. The diagnostic device 103 changes the sampling cycle of the pressure sensor to 1 ms to perform real-time measurement, and transmits the real-time measurement data to the portable terminal 2104 by the short-range wireless communication means 105. The real-time measurement data is displayed on the display screen using an application (not shown) of the portable terminal 2104, and the administrator 133 can confirm whether the pressure sensor 131 is installed and wired correctly.

In addition, the administrator 133 transmits various settings of the diagnostic device 103 by the short-range wireless communication means 105 using the application on the portable terminal 2104, and causes the diagnostic device 103 to register. The setting contents of the diagnostic device 103 include a diagnosis interval and a diagnosis time, a simple diagnosis item, a threshold value for performing a simple diagnosis, a detailed diagnosis item when the diagnosis is abnormal, a type of sensor to be connected, and the like.

Since the diagnostic device of the embodiment does not have a large screen display unit in order to realize low cost and low power consumption, but has a short-range wireless communication means, the administrator can use the portable terminal 2104 on the spot. Measurement data and the like can be confirmed by using. As a result, even in an environment where the communication band of the long-distance wireless communication means is limited, the diagnostic device can be easily introduced and installed regardless of the environment. After the setting is completed, as described in the embodiment, the diagnostic apparatus 103 executes the autonomous diagnostic mode M1, the standby mode M2, the monitor mode M3, and the monitor end confirmation mode M4 under the control of the control unit 200.

(Example 3)
Hereinafter, Example 3 of the present invention will be described with reference to the drawings.
Here, even if the connection of the short-range wireless communication means is temporarily interrupted while the diagnostic device monitors the pressure state of the compressor installed in the production device in real time in the monitor mode M3, continuous monitoring is performed. Explain that the result can be transmitted to the portable terminal.

The administrator 133 moves the portable terminal 2104 provided with the short-range wireless communication means 105 within the communicable range 132 of the short-range wireless communication means 105 of the diagnostic device 103 to establish communication. As a result, the diagnostic apparatus 103 transitions to the monitoring state of the monitor mode M3, changes the sampling cycle of the signal of the pressure sensor 131 to 1 ms in the step S11, and performs real-time measurement in the step S12.

The diagnostic device 103 transmits real-time detailed measurement data to the portable terminal 2104 by the short-range wireless communication means 105. Since the portable terminal 2104 is held in the communicable range 132 of the short-range wireless communication means 105 while being held by the administrator 133, it is unintentionally temporarily out of the communicable range 132 of the short-range wireless communication means 105. In some cases. A procedure for displaying the continuous monitoring result on the portable terminal 2104 even if the device is temporarily removed will be described.

FIG. 7 is a time chart showing changes in the operating state of the diagnostic device 103 of the embodiment with the passage of time. The horizontal axis of the four graphs shows the passage of time.
In the state 301 where the radio wave strength of the short-range wireless communication means 105 is strong between the diagnostic device 103 and the portable terminal 2104, the established state 305 where short-range wireless communication is established between the two, and the diagnostic device 103 is in the monitor mode M3. The monitoring state becomes 309. In the monitoring state 309, the diagnostic device 103 performs detailed diagnosis by real-time measurement as the first monitor diagnostic process, and transmits the data related to the detailed diagnosis to the portable terminal 2104 by the short-range wireless communication means 105 at any time. In this case, the data is not temporarily stored in the internal storage device 208, and the state is 312 without storage.

Here, if the portable terminal 2104 is temporarily disconnected from the communicable range 132 of the short-range wireless communication means 105 and a state 302 in which the radio wave strength is weak occurs, the connection of the short-range wireless communication means 105 is temporarily disconnected. It becomes 306. The diagnostic device 103 constantly monitors whether NFC communication is established during the execution of the monitor mode M3, and when it detects a disconnection of the communication, immediately generates an interrupt process to shift to the monitor end confirmation mode M4. That is, even if the temporary disconnection state 306 is reached, the diagnostic device 103 does not immediately transition to the standby mode M2, and the administrator terminates the monitor whether the communication is temporarily disconnected in the monitor end confirmation mode M4. Therefore, determine whether it was disconnected.

During the period 310 during which the monitor end confirmation mode M4 is being executed, the diagnostic device 103 maintains the monitoring state 309 for a predetermined time to continue real-time measurement, and stores detailed diagnostic data in the internal storage device 208 which is a storage unit. The save operation 313 is performed.

When the radio wave intensity becomes stronger again as in the state 303 within a predetermined time, the short-range wireless communication between the diagnostic device 103 and the portable terminal 2104 is reestablished in the state 307. In this case, the diagnostic device 103 transmits the data stored in the internal storage device 208 and the real-time measurement data to the portable terminal 2104. The real-time measurement data is in the unsaved state 314.

On the other hand, as shown in the state 304 on the right side of the graph of FIG. 7, when the state 308 in which the radio wave strength is weak and the communication is disconnected continues for a predetermined period or more, the administrator sets the monitor mode M3 in the diagnostic device 103. Judge that it has been completed. In this case, the diagnostic device 103 transitions from the state 311 of the monitor end confirmation mode M4 to the standby mode M2, and the data temporarily stored in the internal storage device 208 during the period 315 of the monitor end confirmation mode M4 is not transmitted. In the subsequent standby mode M2 period 316, no data is saved.

The battery 210 of the diagnostic device 103 may back up the power supply to the diagnostic device 103 when the portable terminal 2104 temporarily deviates from the communicable range 132 of the short-range wireless communication means 105. Alternatively, a capacitor or the like that stores electric power by wireless power supply from the portable terminal 2104 may be used.

FIG. 8 is a schematic view of a display screen which is a display unit of the portable terminal 2104 which can be connected to the diagnostic device of the embodiment by short-range wireless communication. The administrator 133 moves the portable terminal 2104 including the short-range wireless communication means 105 to the communicable range 132 of the short-range wireless communication means 105 of the diagnostic device 103. When the diagnostic device 103 shifts to the monitor mode M3, the graph 402 obtained by signal processing the measurement result of the pressure sensor 131 is displayed in real time on the display unit of the portable terminal 2104.

Even if a temporary interruption period 404 occurs between the period 403 and the period 405 when the short-range wireless communication connection is established, when the communication is reestablished, the diagnostic device 103 stores the data stored in the internal storage device 208. And real-time diagnostic data is transmitted to the portable terminal 2104. As a result, even when the communication of the short-range wireless communication means is temporarily disconnected, the detailed diagnosis result can be displayed on the screen of the portable terminal 2104 as a continuous graph including the saved data 406 as shown in FIG. It becomes. Since the graph of the diagnostic data is displayed without interruption, the administrator can appropriately grasp the status of the device to be diagnosed.

[Other Embodiments]
The present invention is not limited to the embodiments and examples described above, and many modifications can be made within the technical idea of the present invention.
The present invention supplies a program that realizes one or more functions of the above-described embodiment to a system or device via a network or storage medium, and one or more processors in the computer of the system or device reads and executes the program. It can also be realized by the processing to be performed. It can also be realized by a circuit (for example, ASIC) that realizes one or more functions.

101 ... Production device / 102 ... Sensor / 103 ... Diagnostic device / 104 ... Portable terminal device / 105 ... Short-range wireless communication means / 106 ... Long-range wireless communication means / 107 ... Gateway / 108 ... Network / 109 ... Database / 110 ... Computer / 200 ... Control unit / 201 ... Sensor / 203 ... Comparer / 204 ... AD converter / 205 ... Signal processor / 206 ... Timer trigger / 208 ... Internal storage device / 209 ... Threshold / 210 ... Battery

Claims (16)

It includes a first wireless communication unit, a second wireless communication unit having a wider communication band than the first wireless communication unit, and a control unit that controls an operation mode.
An autonomous diagnosis mode in which a measurement signal related to the state of the device to be diagnosed is acquired and a simple diagnosis information generated by processing the measurement signal is transmitted from the first wireless communication unit.
When the second wireless communication unit establishes wireless communication with the portable terminal device, it acquires a measurement signal related to the state of the device to be diagnosed and performs a process different from the autonomous diagnosis mode. It is possible to execute a monitor mode in which the detailed diagnostic information generated in the above is transmitted from the second wireless communication unit to the portable terminal device.
A diagnostic device characterized by that. The first wireless communication unit is a long-distance wireless communication communication unit, and the second wireless communication unit is a short-range wireless communication communication unit.
The diagnostic device according to claim 1. When the autonomous diagnosis mode and the monitor mode are not executed, the standby mode in which power consumption is suppressed can be executed.
The diagnostic apparatus according to claim 1 or 2. A trigger unit that generates a trigger at a predetermined timing is provided, and the trigger shifts from the standby mode to the autonomous diagnosis mode.
The diagnostic device according to claim 3, wherein the diagnostic device is characterized by the above. When the wireless communication between the second wireless communication unit and the portable terminal device is disconnected during the execution of the monitor mode, the wireless communication between the portable terminal device and the portable terminal device is disconnected even after a predetermined time has elapsed. If the wireless communication is not restored, the mode shifts to the standby mode.
The diagnostic apparatus according to claim 3 or 4. In the monitor mode, a measurement signal relating to the state of the device to be diagnosed is acquired at a cycle and / or the number of samples different from when the simple diagnosis information is generated in the autonomous diagnosis mode.
The diagnostic apparatus according to any one of claims 1 to 5. A power receiving coil for receiving wireless power supply from the portable terminal device is provided.
The diagnostic apparatus according to any one of claims 1 to 6, wherein the diagnostic apparatus is characterized in that. The diagnostic device according to any one of claims 1 to 7, a gateway capable of receiving a signal transmitted by the first wireless communication unit of the diagnostic device, and the second wireless communication unit of the diagnostic device. A portable terminal device capable of establishing communication with and
A diagnostic system characterized by that. The portable terminal device includes a display unit capable of displaying information transmitted from the second wireless communication unit of the diagnostic device.
The diagnostic system according to claim 8, wherein the diagnostic system is characterized in that. The diagnostic device
The measurement signal is taken from the sensor that measures the state of the device to be diagnosed, the first signal processing is performed, and the presence or absence of an abnormality in the device to be diagnosed is determined based on the result of the first signal processing. Judgment processing and
The determination result transmission process of transmitting the information related to the result of the determination process from the first wireless communication unit is executed.
When it is determined in the determination process that there is an abnormality in the device to be diagnosed,
Further, detailed diagnostic storage processing that takes in the measurement signal from the sensor, performs the second signal processing having a larger calculation amount than the first signal processing, and stores the result of the second signal processing in the storage unit. And run
When communication is established between the second wireless communication unit having a communication band larger than that of the first wireless communication unit and the portable terminal device after the detailed diagnostic storage process,
The detailed diagnosis result transmission process of transmitting the result of the second signal processing stored in the storage unit from the second wireless communication unit to the portable terminal device is executed.
A diagnostic method characterized by that. If communication is continuously established between the second wireless communication unit and the portable terminal device even after the detailed diagnosis result transmission process is executed,
The measurement signal is taken from the sensor, a third signal processing having a larger calculation amount than the first signal processing is performed, and the result of the third signal processing can be obtained from the second wireless communication unit. Execute the first monitor diagnostic process to be sent to the portable terminal device,
The diagnostic method according to claim 10, characterized in that. When communication is established between the second wireless communication unit and the portable terminal device after determining that there is no abnormality in the device to be diagnosed in the determination process,
The measurement signal is taken from the sensor, the fourth signal processing having a larger calculation amount than the first signal processing is performed, and the result of the fourth signal processing can be obtained from the second wireless communication unit. Executes a second monitor diagnostic process to be sent to the portable terminal device,
The diagnostic method according to claim 10 or 11. When communication is cut off after communication is established between the second wireless communication unit and the portable terminal device, communication is restored between the portable terminal device and the portable terminal device even after a predetermined time has elapsed. If not, shift to standby mode with reduced power consumption.
The diagnostic method according to any one of claims 10 to 12, characterized in that. The determination process is executed based on the trigger generated by the trigger unit at a predetermined timing.
The diagnostic method according to any one of claims 10 to 13, characterized in that. While communication is established between the second wireless communication unit and the portable terminal device, the diagnostic device receives wireless power from the portable terminal device.
The diagnostic method according to any one of claims 10 to 14, characterized in that. The diagnostic method according to any one of claims 10 to 15, wherein the information received from the diagnostic device is displayed on the display unit of the portable terminal device.

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