JP4246417B2 - Magnet float level gauge fault diagnosis system - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
  This invention is based on a magnet float type level gauge installed in each user.Signals from various sensors for fault monitoringIs input to the fault monitoring server via the communication network.Signals from various sensorsThe present invention relates to a magnet float type level gauge fault diagnosis system that specifies a fault site by applying a predetermined fault diagnosis logic and returns fault repair information corresponding to the specified fault site to a user through a communication network.
[0002]
[Prior art]
As a kind of conventional magnetic float type liquid level gauge, as shown in the longitudinal sectional view of FIG. 23 (a) and the transverse sectional view of FIG. 23 (b), the tank 1 is communicated with an upper communicating pipe 2U and a lower communicating pipe 2L. In some cases, a float 4 having a magnet MG is suspended in a chamber 3 made of a non-magnetic material having a liquid level corresponding to the liquid level in the tank 1, and the liquid level in the tank 1 is measured from the floating position. The upper end flange F1 and the lower end flange F2 of the chamber 3 are provided with lids.
[0003]
This magnet float type level gauge rotates in a circumferential direction by a predetermined angle when attracting or repelling the magnet MG along the chamber 3, and changes the color of the circumferential surface from white to red. Indicators 6 in which a plurality of indicators 5 made of magnets are arranged in a horizontal direction are arranged along the float floating direction in the chamber 3.
[0004]
When the float 4 moves in the chamber 3 according to the movement of the liquid level in the tank 1, each indicator 5 sequentially changes the color of the circumferential surface from white to red by the magnetic force of the magnet MG, and the red range is continuously changed. By changing, the liquid level in the tank 1 is displayed.
[0005]
When measuring the water level in a tank by visually observing the discoloration range of multiple indicators, conventional human float type liquid level gauges determine the validity of the current status display from the past operation history of a hot water boiler, for example. By checking, it was judged whether the indicator display shows the actual water level. When an abnormality was found in the liquid level display by the indicator, the liquid level gauge was disassembled and inspected to identify the failed part.
[0006]
In addition, when a remote water level detector that can check the water level remotely is attached to the magnetic float type liquid level gauge, the indicator of the magnetic float type liquid level gauge is compared with the detection value of the remote water level detector attached. If it was judged that the detected value was different from the display on the indicator, the magnet float type liquid level gauge was disassembled and inspected to identify the faulty part.
[0007]
[Problems to be solved by the invention]
Previously, when an abnormality was found in the liquid level display of the magnet float type liquid level gauge, the liquid level gauge was disassembled and inspected to identify the faulty part, but even if the faulty part was actually specified, the liquid level gauge If the model plate is damaged after the installation of the product, it becomes difficult to request replacement parts according to the model, or even if you obtain replacement parts, you will not know the replacement method and contact the manufacturer. As a result, it takes time to repair the fault and affects the operation of the plant.
[0008]
In addition, since the clerk does not always monitor the failure of the magnetic float type liquid level gauge, the degree of failure may have progressed remarkably at the time of judging the failure visually, in which case the failure repair is quite significant. It will take time.
[0009]
This invention was made to solve the above-mentioned problems, and the manufacturer automatically monitors the fault of the magnet float type liquid level gauge remotely whenever necessary in accordance with a contract with each user to determine the fault. An object of the present invention is to provide a magnet float type liquid level gauge fault diagnosis system that can provide fault repair information according to a fault site to a user through a communication network.
[0010]
[Means for Solving the Problems]
  The fault diagnosis system for a magnetic float type liquid level gauge according to the invention of claim 1 floats a float provided with a magnet in a non-magnetic chamber communicated with a liquid container and having a liquid level corresponding to the liquid level in the liquid container. The indicator which receives the action of the magnetic field of the magnet is arranged along the chamber to display the liquid level, and the user ID transmitted from the magnet float type liquid level meter arranged for each user and for fault monitoring The signals from the various sensors are sent to the failure monitoring server through the communication network, and the signals from the various sensors are processed by the failure monitoring server., Float submersion, internal pressure drop, float stick and magnet magnetic force dropIn addition to performing failure diagnosis, when it is determined that the failure diagnosis is abnormal, failure repair information is sent to the user through the communication network, and the failure monitoring server sends signals from the various sensors.Along with the user IDSensor signal input means to input and inputThe contents of the signals from the various sensors are confirmed by determining which user has transmitted the signal from the user ID and determining that the input of the signals from the various sensors has been completed.Signal content determination means and the signalContentWith judgment meansConfirmationDepending on the contents of the signals from the various sensors, a predetermined failure diagnosis processing logicFloat submersion, internal pressure drop, float stick and magnet magnetic force dropDiagnostic logic determination means for determining abnormality and the diagnosis logic determination meansThe float is submerged, the internal pressure is decreased, the float stick or magnet is decreasedA failure determination means for determining whether or not an abnormality has been determined, and the diagnostic logic determination means;The float is submerged, the internal pressure is decreased, the float stick or magnet is decreasedWhen it is determined by the failure determination means that it is determined as abnormal,Abnormal content of whether the abnormality determined by the diagnostic logic determination means is the float submergence / internal pressure drop, float stick or magnet magnetic force dropAnd the user IDChangnaiThe name of the part to be replaced according to the contents, the manufacturing number of the liquid level gauge of the user destination corresponding to the user ID, the part number of the part name to be replaced corresponding to the manufacturing number, and the number of parts in stock of the part number Alternatively, repair information search means for searching a plurality of databases each storing a standard delivery date, a work procedure manual number of a repair work corresponding to the part number of the part to be replaced, a work time spent on the repair work, and the number of workers, and a search Repair information providing means for sending the stock quantity or standard delivery date, work procedure manual number, work time, and number of workers to the user as the fault repair information via the communication network, and the diagnostic logic judging means includes the fault monitoring First failure diagnosing means for determining float submergence / decrease in internal pressure based on signals from various sensors, and second for determining a float stick Failure diagnosis means and third failure diagnosis means for determining a decrease in magnet magnetic force, wherein the first failure diagnosis means is a position of a float magnet in the chamber that is one of the signals from the various sensors. The float is submerged and the internal pressure drop is determined based on a comparison between the signal and an actual water level signal in the liquid container based on the liquid phase pressure of the chamber, which is one of the signals from the various sensors. The diagnosis unit determines a float stick based on a comparison between a unit time change rate of the position signal and a unit time change rate of the actual water level signal, and the third failure diagnosis unit repeats the position signal. Decrease in magnet magnetic force based on the level change.
[0014]
  Claim2The magnet float type liquid level gauge fault diagnosis system according to the invention is a liquid phasePartThe actual water level signal is calculated with a value obtained by correcting the pressure with the specific gravity of the liquid, and provided to the first and second failure diagnosis means.
[0015]
  Claim3The magnet float type liquid level gauge fault diagnosis system according to the invention is a liquid phase of a chamber.PartPressure and gas phasePartPressurePowerThe pressure difference between the gas phasePartActual value corrected with specific gravity calculated based on saturation pressure calculated from pressurewaterThe position signal is calculated and used for the first and second failure diagnosis means.
[0016]
  Claim4The magnet float type liquid level gauge fault diagnosis system according to the invention is a liquid phase of a chamber.PartInstead of the actual water level signal in the liquid container based on the pressure, the water level information detected from the liquid container body remotely from the magnet float type level gauge is used as the actual water level signal.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a magnet float type level gauge failure diagnosis system according to the present invention will be described with reference to the accompanying drawings. FIG. 1 is a block diagram of a magnet float type liquid level gauge failure diagnosis system according to the present invention, and FIG. 2 is a diagram functionally showing software processing of a computer on the failure monitoring server (maker) side in this system. This is the basic configuration.
[0019]
This system uses a magnet float type liquid level gauge with each sensor for failure monitoring. From users (customers) CL1 to CL5 who have a maintenance contract, and each sensor installed in the magnet float type liquid level gauge A failure monitoring server 11S that performs failure diagnosis based on the output signal and distributes failure repair information to contract users CL1 to CL5 when a failure is detected is connected by a communication network N.
[0020]
The communication network N can be a LAN, the Internet, a personal computer communication network via a public line, or any other network using wired or wireless communication. In the failure monitoring server 11S, a computer 111 for performing failure diagnosis processing and failure repair information search, an input device 112 for inputting information by an operator such as a keypad or a pointing device (mouse, pen, etc.), registered later An output device 113 for visually displaying the database information, failure diagnosis processing result, and failure repair information to be displayed on a screen or a paper medium is arranged.
[0021]
The storage unit (not shown) of the failure monitoring server 11S includes an abnormality / part replacement database DB1, a product information database DB2, a parts information database DB3, a work procedure manual database DB4, a man-hour management database DB5, and a user information database DB6. Has been built.
[0022]
As the output device 113, for example, a CRT display, a liquid crystal display, a printer device or the like is used. As a storage device for constructing the database or storing a program executed by the computer 111 and a large amount of data files, a magnetic disk, an optical disk, a magneto-optical disk, a semiconductor memory, or the like is used.
[0023]
The communication cable 115 is for transmitting information like a telephone line, and it is desirable that a large amount of data can be communicated at high speed like an optical cable. In this case, when a configuration is adopted in which data is transmitted / received to / from the communication network N using a wireless communication line, a wireless communication line interface is provided instead of the communication cable 115.
[0024]
Although not shown, the users CL1 to CL5 convert signals from various sensors for failure monitoring provided in the magnet float type liquid level gauge into transmission signals for the failure monitoring server 11S, and communication cables 114-1 to 114-. 5 includes a transmission / reception unit that receives the failure repair information transmitted from the failure monitoring server 11S through the communication network N to the communication network N and displays the screen.
[0025]
Next, the link structure of each database will be described with reference to FIG.
First, when a signal is input from a failure monitoring sensor provided in a magnet float type liquid level meter installed in a customer, that is, a user CL, through the communication network N, a failure of the magnet float type liquid level meter is caused based on the signal. When the diagnosis is made and abnormality is determined, the abnormality / part replacement database DB1 for searching for a part to be replaced with the abnormality content as a keyword, the manufacturing number of the user's destination magnetic float type liquid level gauge searched from the user database (not shown) The product information database DB2 that searches for the part number of a replacement part using the keyword as a keyword, the parts information database DB3 that searches the inventory status of the part using the part number as a keyword, and the work of the part using the part number searched from the product information database DB2 as a keyword Procedure manual number indicating the procedure (procedure number) Search for work procedure manual database DB4, work time according to the failure repair to the instructions number as a keyword, man-hour management database DB5 to search for the number of workers is linked, respectively.
[0026]
The stock quantity or standard delivery date of parts retrieved from the parts information database DB3, the procedure manual number retrieved from the work procedure database DB4, the work time retrieved from the man-hour management database DB5, and the number of workers are communication network as failure repair information. N to the user CL.
[0027]
Next, the development to the next database search based on the details of each database and the database search result will be described with reference to FIGS.
As shown in FIG. 18 (a), when the abnormality content is determined as a result of the failure diagnosis, from the abnormality / part replacement database DB1 indicating the content in FIG. Search for floats, chambers, and gaskets that are replacement parts. Next, as shown in FIG. 6C, the retrieved replacement part is sent to the product information database DB2 as a corresponding part name for replacement.
[0028]
Next, as shown in FIG. 19 (a), when the corresponding part name and production number are sent to the product information database DB2, as shown in FIG. 19 (b), the model number of the liquid level gauge is retrieved from the production number. The part number is searched from the manufacturing number and the corresponding part name. If the part name is float, the part number is L000000, and if the part name is a chamber, the part number is L000001. Further, as shown in FIG. 6C, the retrieved production number and part name are sent to the parts information database DB3 and work procedure database DB4 as the part names to be replaced.
[0029]
Next, as shown in FIG. 20 (a), when the replacement target part name is sent to the part information database DB3, the inventory quantity and standard delivery date of the corresponding part are retrieved from the part number as shown in FIG. 20 (b). . If the part number is L000000, it is searched that the stock quantity of the float is 15, and the standard delivery time is 3 weeks (W). Next, the retrieved inventory quantity or standard delivery date is provided to the user as failure repair information as shown in FIG.
[0030]
Next, as shown in FIG. 21 (a), when the replacement target part (part number) is sent to the work procedure manual database DB4, the procedure manual number is retrieved from the part number as shown in FIG. 21 (b). . The work procedure manual number is provided to the user as failure repair information as shown in FIG. 5C, and is sent to the man-hour management database DB5.
[0031]
Next, when the work procedure manual number is sent to the man-hour management database DB5 as shown in FIG. 22 (a), the standard work time and necessary work required for the work from the work procedure manual number as shown in FIG. 22 (b). The number of persons is retrieved, and the standard work time and the number of necessary workers are provided to the user as failure repair information as shown in FIG.
[0032]
Next, the arrangement of the failure monitoring sensor provided in the magnet float type level gauge installed in each user will be described with reference to FIGS.
[0033]
User CL1
FIG. 3 is a configuration diagram of a magnet float type level gauge installed in the user CL1.
In the figure, the same reference numerals as those in FIG. 23 denote the same or corresponding parts.
3 (a) and 3 (b) show a longitudinal sectional view and a transverse sectional view of the magnet float type liquid level gauge, respectively. FIG. 2C is a schematic configuration diagram of the magnetostrictive sensor 7. In this magnet float type liquid level gauge, the magnetostrictive sensor 7 is arranged along the longitudinal direction of the chamber 3 (floating direction of the float 4).
[0034]
The chamber 3 is perforated from the lower end flange F2 toward the liquid phase portion, and one end of the capillary tube T is inserted into the hole portion, the other end is guided to the lower pressure sensor 8L, and the pressure of the liquid phase portion in the chamber 3 is measured. Based on the measurement result, the actual water level in the chamber 3 (tank 1) is measured.
[0035]
Here, the operation principle of the magnetostrictive sensor will be described.
As shown in FIG. 8A, when the magnetostrictive sensor 7 momentarily applies a magnetic field to the end of the magnetostrictive line MS housed in a non-magnetic cylinder (not shown) via the drive coil DC, the magnetostrictive line 7 A portion to which a magnetic field is applied in the MS is momentarily extended by ΔL due to a magnetostriction phenomenon to generate a pulse signal (magnetostriction line generation signal), which is propagated as an ultrasonic vibration in the axial direction of the magnetostriction line MS. A receive coil RC is wound over the entire length of the magnetostrictive line MS, and a pulse voltage is generated from the receive coil RC when the ultrasonic vibration reaches the position of the magnet generator (magnet MG housed in the float 4).
[0036]
Since the time from when a magnetic field is applied to the drive coil DC to when the pulse voltage is generated at the receive coil RC varies depending on the position of the magnetic generator, the time from the application of the magnetic field to the drive coil DC to the generation of the pulse voltage and the float By obtaining the relationship with the position, the float position can be obtained from the pulse voltage generation time.
[0037]
As an example of a method for converting the pulse voltage generation time into an analog signal and outputting it, a constant DC voltage is applied to the integrator from the time when a magnetic field is applied to the drive coil DC until the pulse voltage is generated in the receive coil RC. The pulse voltage generation time, that is, the float position can also be obtained from the integrated value.
[0038]
Alternatively, the pulse voltage generation time may be measured by setting a gate circuit, opening the gate from application of the magnetic field to pulse voltage generation, inputting a reference clock signal, and counting.
[0039]
User CL2
4 (a), 4 (b), and 4 (c) are configuration diagrams of a magnet float type level gauge installed in the user CL2.
This magnet float type liquid level gauge is provided with a temperature sensor TS for detecting the temperature of the liquid phase portion at the lower end flange F2 of the chamber 3 in addition to the configuration of the magnet float type liquid level gauge shown in FIG.
[0040]
User CL3
FIGS. 5A, 5B, and 5C are configuration diagrams of a magnet float type level gauge installed in the user CL3. In addition to the configuration of the liquid level gauge shown in FIG. 4, the magnet float type liquid level gauge includes an upper pressure sensor 8 </ b> U that detects the pressure in the gas phase portion at the upper end flange F <b> 1 of the chamber 3.
[0041]
User CL4
FIG. 6 is a configuration diagram of a magnet float type level gauge installed in the user CL4.
This magnet float type liquid level gauge, for example, replaces the lower pressure sensor 8L provided in the magnet float type liquid level gauge 3 whose configuration is shown in FIG. 3A with a remote water level detector (pressure transmitter etc.) 10 as a magnet. It is attached to the float type liquid level gauge 3.
[0042]
User CL5
FIGS. 7A and 7B are configuration diagrams of a magnet float type liquid level gauge installed in the user CL5. This magnet float type liquid level gauge uses a magnetic switch computing unit 11 instead of the magnetostrictive sensor 7.
[0043]
  Further, in each of the above-mentioned magnet float type liquid level gauges, the magnetic force change of the magnet MG is calculated and determined based on the output of the magnetostrictive sensor 7, but this magnet float type liquid level gauge directly measures the magnetic force of the magnet MG in the float 4. A magnetic force detector 12 comprising a Gauss meter is provided. FIG. 2C shows the magnetic switch calculator 11. As shown in FIG. 8B, the magnetic switch computing unit 11 connects resistors R1 to Rn (same resistance value) in parallel between the terminals T1 and T2, and between the terminal T2 and connection points P1 to Pn of each resistor. Reed switch that is turned on by the magnetic force of the magnet MG provided on the float 4S1-SnConnect.
[0044]
  According to this configuration, if the water level is high and the float 4 is raised, the reed switchS1-SnIs ON, the combined resistance value measured between the terminals T1 and T2 is R1 // R2 // R3 // .. Rn obtained by combining resistors R1 to Rn in parallel.
[0045]
  As the water level in the tank drops, the reed switch turns off when the float 4 descends.Chi SInstead, the number of resistors connected in parallel decreases and the combined resistance value increases. Therefore, the float position (tank liquid level) can be detected by converting the change in the combined resistance value into a current.
[0046]
That is, when the float floats up and the number of resistors connected in parallel is the largest, the combined resistance value is the smallest and the most current flows. However, when the float falls due to a drop in the water level, the number of resistors connected in parallel decreases due to the reed switch RS being turned off, and the combined resistance value increases.
[0047]
As a result, the current I flowing from the terminal is I = E / (R1 // R2 // R3 //. Rn) in a state where the float is lifted. /(R2//R3//..Rn), E / (R3 // .. Rn),... E / Rn. The current I output from the magnetic switch calculator 11 is amplified by a resistance current converter and converted into water level data.
[0048]
Next, a failure diagnosis method for the magnet float type liquid level gauge of each user in the failure monitoring server 11S will be described based on the flowchart shown in FIG. 9 and the failure diagnosis logic shown in FIGS.
First, in performing fault diagnosis of the magnet float type liquid level gauge based on the sensor signal from the user CL in the computer 111 of the fault monitoring server 11S, first, input data, calculation results, database data, etc., which are sensor signals, are temporarily stored. The memory area to be initialized is initialized (step S1). Next, customer (user) data captured through the communication network N is input (step S3). In the customer data, a user ID and various sensor signals corresponding to the serial number of the magnet float type liquid level gauge stored in the user database DB 6 in advance are stored in a predetermined format.
Therefore, the failure monitoring server 11S can find out the serial number by searching the user database DB6 with the user ID.
[0049]
If it is determined that the user who has sent the customer data from the user ID is the user CL1 (step S5), it is determined whether the reading of the sensor signal is completed (step S7). When the reading of the sensor signal is completed, a failure diagnosis process is started.
[0050]
As failure diagnosis processing, first, failure diagnosis 9A based on float submersion / internal pressure reduction calculation is performed from the magnetostrictive sensor signal and the lower pressure sensor signal (step S31). As shown in FIG. 10, the failure diagnosis 9A compares the sensor signal corresponding to the position of the float 4 output from the magnetostrictive sensor 7 with the sensor signal corresponding to the actual water level in the tank 1 output from the lower pressure sensor. Then, the deviation ΔL is obtained (step 9A1).
[0051]
At this time, when the float is submerged, for example, when the float sinks to the bottom of the chamber 3, the water level calculated based on the magnetostrictive sensor output is “0”, but the actual water level is not “0”. appear. Therefore, when the deviation ΔL is compared with the reference deviation value set in advance in step S9A2, the comparison unit COMa causes the deviation ΔL to exceed the reference deviation value.
[0052]
Next, failure diagnosis 9B based on the float stick calculation is performed from the magnetostrictive sensor signal and the lower pressure sensor signal (step S33).
[0053]
In this failure diagnosis 9B, when a stick is generated due to scale attachment such as rust on the float, the float displacement amount detected based on the output of the magnetostrictive sensor 7 has a smaller rate of change with time and eventually changes. The float stick determination process is performed by paying attention to the fact that the position in the stick state is continuously output as the float position from the magnetostrictive sensor 7 as shown in FIG.
[0054]
As the float stick calculation 9B, the float displacement amount based on the output of the magnetostrictive sensor 7 is input and differentiated to calculate the rate of change per unit time (step 9B11). The calculated change rate of the float displacement amount and the lower limit value of the change rate set in step 9B21 are compared by the comparison unit COMb1, and when the change rate is equal to or lower than the lower limit value, a logic “H” level signal is output.
[0055]
On the other hand, the float displacement amount at the actual water level based on the output of the lower pressure sensor 8L is input and differentiated to calculate the rate of change per unit time (step 9B12). Then, the calculated change rate and the upper limit value of the change rate set in step 9B22 are compared by the comparison unit COMb2, and when the change rate is equal to or higher than the upper limit value, a logic “H” level signal is output.
[0056]
When the logical “H” level signal output from the comparison units COMb1 and COMb2 is subjected to a logical product operation in the logical product operation unit AD1, a logical “H” level signal is output to the counter unit CT. When the counter unit CT counts that the logic “H” level signal has been output for a preset time, it determines that the magnet float type liquid level gauge has failed due to the float stick, and outputs a failure determination signal.
[0057]
As is apparent from FIG. 11, the failure determination is based on a change in the displacement amount of the float detected by the magnetostrictive sensor 7 even though the float displacement amount based on the actual water level changes at a constant rate of change. If the rate is less than or equal to the set lower limit value, it is determined that a stick has occurred in the float 4.
[0058]
Next, failure diagnosis 9C based on the magnet magnetic force reduction calculation is performed from the magnetostrictive sensor signal (step S35).
[0059]
  This fault diagnosis 9CWhen the magnetic force of the magnet MG built in the float 4 decreases, the magnetostrictive sensor 12 receiving the magnetic field of the magnet MG repeatedly changes the sensor output (magnetic force) in small increments as shown in FIG. 12 (hunting). The magnet magnetic force decrease determination process is performed by paying attention to the sudden occurrence of.
[0060]
As the magnet magnetic force reduction calculation, the sensor output from the magnetostrictive sensor 7 is input, and the peak value and period are calculated together with the frequency (step 9C1). The calculated peak value is input to the comparator COMc1, where it is compared with the peak value set in step 9C21, and when the calculated peak value is greater than or equal to the set value, a logic “H” level signal is output. .
[0061]
The calculated cycle is input to the comparison unit COMc2, where it is compared with the cycle set in step 9C21. When the calculated cycle is earlier than the set value, a logic “H” level signal is output. The logic level signals output from the respective comparison units COMc1 and 2 are input to the AND operation unit AD2, and when any logic signal is an “H” level signal, the magnetic float type liquid level gauge is caused by a decrease in the magnetic force of the magnet in the float. A failure is determined and a failure determination signal is output.
[0062]
As described above, it is determined whether or not a failure is determined in each failure calculation process. If the failure is not determined, the process returns to step S3 (step S37), and the next customer data is input. At this time, if a failure determination is made by any failure diagnosis, the various databases DB1 to DB5 shown in FIG. 17 are searched, and the number of replacement parts in stock according to the abnormality content or the standard delivery date and work time spent for repair work Then, the number of workers and the number of the work procedure manual for the repair work are read out (step S39). The contents read from these databases are sent as failure repair information to the user CL1 through the communication network N (step S41). After sending the information, the process returns to step S3 (step S37), and the next customer data is input.
[0063]
If it is determined that the user who has sent the customer data from the user ID is the user CL2 (step S9), it is determined whether the reading of the sensor signal is completed (step S11). If the reading of the sensor signal is completed, the fault diagnosis process is started.
[0064]
  Figure 13 shows the userCL2 is a diagram showing a configuration of failure diagnosis processing 9-2 for 2. FIG. In this failure diagnosis process, in addition to the configuration of the failure diagnosis process 9-1 for the user 1, the liquid specific gravity is corrected and calculated based on the temperature of the liquid phase portion detected by the temperature sensor TS, and the pressure correction value of the lower pressure sensor 8L is calculated. A correction calculation process 8A for obtaining a is provided.
[0065]
That is, since the liquid has a molecular density that changes with temperature and the specific gravity changes, the buoyancy with respect to the float 4 also changes. This is because the actual water level based on the value needs to be corrected by the specific gravity.
[0066]
In this correction calculation process 8A, the specific gravity of the liquid is corrected and calculated based on the temperature of the liquid phase portion detected by the temperature sensor TS (step 8A1), and then the pressure b detected by the pressure sensor 8L is corrected by the correction value a. And output (step 8A2).
[0067]
After the correction of the pressure in the liquid phase part, in the failure diagnosis 9A in step S31 and the failure diagnosis 9B in step S33, the funnel submersion / internal pressure reduction calculation 9A and the float stick calculation 9B are performed based on the actual water level based on the corrected pressure. Perform a fault determination of the liquid level gauge. Other processes are the same as those of the user CL1.
With such a failure diagnosis method, even when the liquid specific gravity in the tank changes depending on the operation method and environmental conditions, the failure diagnosis can be performed accurately.
[0068]
If it is determined that the user who has sent the customer data from the user ID is the user CL3 (step S15), it is determined whether reading of the sensor signal is completed (step S17). If the reading of the sensor signal is completed, the fault diagnosis process is started.
[0069]
FIG. 14 is a diagram illustrating the configuration of the failure diagnosis processing 9-3 for the user CL3. In addition to the configuration of the failure diagnosis processing 9-2 for the user CL2, each pressure detected by the upper pressure sensor 8U and the lower pressure sensor 8L. Is corrected with a specific gravity a calculated based on the saturation pressure calculated from the pressure detected by the upper pressure sensor 8U, and is output.
[0070]
In the pressure correction process 8B, a difference in pressure (differential pressure) detected by the upper pressure sensor 8U and the lower pressure sensor 8L is obtained (step 8B4), and a saturated pressure is calculated from the pressure detected by the upper pressure sensor 8U. (Step 8B2), and the liquid specific gravity in the tank 1 is obtained based on the saturation pressure calculation result (Step 8B3). Next, the differential pressure is corrected by the liquid specific gravity and output to the float submersion / internal pressure reduction calculation unit 9A and the float stick calculation unit 9B to be used for each calculation (step 8B1). Other processes are the same as those of the user CL1.
[0071]
In this way, by correcting the liquid specific gravity with the pressure difference between the gas phase and the liquid phase, pressure other than atmospheric pressure is applied to the tank 1 depending on the operation method and environmental conditions, and the liquid specific gravity in the tank 1 is increased. Even when the change occurs, fault diagnosis can be performed accurately.
[0072]
If it is determined that the user who has sent the customer data from the user ID is the user CL4 (step S21), it is determined whether reading of the sensor signal is completed (step S23). When the reading of the sensor signal is completed, a failure diagnosis process is started.
[0073]
In the failure diagnosis process for the users L1 to L3, the actual water level is calculated from the detection results of the lower pressure sensor 8L or the lower pressure sensor 8L and the upper pressure sensor 8U and used for various failure diagnosis.
[0074]
In this fault diagnosis process, the actual water level detected by the existing remote water level detector provided in the magnet float type liquid level gauge in place of the lower pressure sensor 8L and the magnetostrictive sensor 7 provided in the magnet float type liquid level gauge are detected. Various fault diagnosis is performed based on the float position.
[0075]
FIG. 15 is a diagram showing a configuration of the failure diagnosis processing 9-4 for the user CL4. The configuration is the same as the failure diagnosis processing for the user CL1, and the failure diagnosis processing includes float submersion / internal pressure reduction calculation processing 9A, float stick. Except that the actual water level input to the arithmetic processing 9B is input from the remote water level detector 10, it is the same as the failure diagnosis processing for the user CL1.
[0076]
As described above, if the remote water level detector 10 is provided together with the magnet float type liquid level gauge, the failure detection can be easily performed by comparing the results of both water level detections.
[0077]
If it is determined that the user who has sent the customer data from the user ID is the user CL5 (step S25), it is determined whether reading of the sensor signal is completed (step S27). If the reading of the sensor signal is completed, the failure diagnosis process 9D is entered (step S29).
[0078]
  FIG. 16 is a diagram showing a configuration of failure diagnosis processing 9-5 for the user CL5. In the magnet magnetic force reduction calculation processing 9D in the failure diagnosis processing 9-5, the float 4 input from the magnetic force detector 12 made of a gauss meter. The magnetic force signal level of the magnet MG in the inside and the magnetic force decrease determination value preset in step S9B1 are compared with the comparison unit COMd.Compare withWhen the magnetic signal level is equal to or lower than the magnetic force decrease determination value, the magnetic force decrease is determined.
[0079]
  It should be noted that the float submersion / internal pressure reduction calculation process 9A andFThe rotstick calculation processing 9B is the same as the failure diagnosis processing for the user CL1, except that the float floating position is taken in based on the output signal of the magnetic switch calculator 12 instead of the output signal of the magnetostrictive sensor 7, and the failure diagnosis processing is performed.
[0080]
【The invention's effect】
  According to this invention, from the magnet float type level gauge installed in each userSignals from various sensors for fault monitoringIs input to the fault monitoring server via the communication network.Signals from various sensorsWhen the failure part is specified by applying a predetermined failure diagnosis logic, failure repair information corresponding to the specified failure part can be immediately provided to the user through the communication network, so that the burden of failure monitoring of the user is reduced. In addition, there is an effect that the failure recovery can be performed at an early stage.
[Brief description of the drawings]
FIG. 1 is an overall configuration diagram of a magnet float type level gauge fault diagnosis system according to the present invention.
FIG. 2 is a basic configuration diagram of a magnet float type level gauge fault diagnosis system according to the present invention.
FIG. 3 is a configuration diagram of a magnet float type liquid level gauge installed in a client CL1.
FIG. 4 is a configuration diagram of a magnet float type liquid level gauge installed in the client CL2.
FIG. 5 is a configuration diagram of a magnet float type liquid level gauge installed in the client CL3.
FIG. 6 is a configuration diagram of a magnet float type liquid level gauge installed in the client 4;
FIG. 7 is a configuration diagram of a magnet float type liquid level gauge installed in the client 5;
FIG. 8A is a diagram for explaining the operation principle of the magnetostrictive sensor, and FIG. 8B is a basic configuration diagram of a magnetic switch computing unit.
FIG. 9 is a diagram illustrating a processing operation performed by a failure monitoring server.
FIG. 10 is a diagram for explaining a failure diagnosis process of a magnet float type liquid level meter disposed in a user CL1.
FIG. 11 is a diagram illustrating a float stick.
FIG. 12 is a diagram for explaining a decrease in magnetic force of the magnet in the float.
FIG. 13 is a diagram for explaining a failure diagnosis process of a magnet float type liquid level meter disposed in a user CL2.
FIG. 14 is a diagram for explaining a failure diagnosis process of a magnet float type liquid level meter disposed in a user CL3.
FIG. 15 is a diagram for explaining a failure diagnosis process of a magnet float type liquid level gauge disposed in a user CL4.
FIG. 16 is a diagram for explaining a failure diagnosis process of a magnet float type liquid level gauge disposed in a user CL5.
FIG. 17 is a diagram illustrating a link state of each database constructed in the failure monitoring server according to the present embodiment.
FIG. 18 is a diagram showing the contents of the abnormality / part replacement database shown in FIG. 17;
FIG. 19 is a diagram showing the contents of the product information database shown in FIG.
FIG. 20 is a diagram showing the contents of the component information database shown in FIG.
FIG. 21 is a diagram showing the contents of the work procedure database shown in FIG. 17;
FIG. 22 is a diagram showing the contents of a man-hour management database shown in FIG. 17;
FIG. 23 is a block diagram of a conventional magnet float type liquid level gauge.
[Explanation of symbols]
11S Fault monitoring server
111 computer
DB1 to DB6 database
N communication network
CL1 to CL5 users
101 Sensor signal input means
103 Signal content judging means
105 Diagnostic logic determination means
107 Failure determination means
109 Repair information retrieval means
110 Repair information provision means

Claims (4)

A float provided with a magnet is suspended in a non-magnetic chamber having a liquid level that communicates with the liquid container and corresponds to the liquid level in the liquid container, and an indicator that receives the action of the magnetic field of the magnet is provided along the chamber. The user ID transmitted from the magnet float type liquid level meter arranged for each user and displaying the liquid level and signals from various sensors for fault monitoring are sent to the fault monitoring server through the communication network, The fault monitoring server processes signals from the various sensors to perform fault diagnosis of float submergence / internal pressure drop, float stick and magnet magnetic force drop, and when the fault diagnosis determines that an abnormality has occurred, Sent to the user through the communication network,
The failure monitoring server is configured to input a sensor signal input unit that inputs signals from the various sensors together with the user ID, and to determine which user has transmitted the signal from the input user ID. by determining that the reading of signals from the various sensors has been completed, the signal content determining means for determining the content of the signal from the various sensors, the signals from the various sensors has been identified in the signal content determining means the float submerged-pressure reduction at the predetermined failure diagnosis processing logic depending on the content, and detect logic determination means for performing abnormality determination of the float sticks and magnet magnetic force decreases, the float submerged-pressure drop in the diagnostic logic determining unit, a float failure determination determines whether an abnormality is judged stick or magnet force reduction And stage, the float submerged-pressure drop in the diagnostic logic determining unit, when it is determined by the failure determination means that an abnormality is judged float stick or magnet force decreases, abnormality it is determined by the diagnostic logic determination means or wherein a float submerged-pressure drop, based on whether the abnormal content is or magnet force reduction is a float stick with the user ID, part name should be replaced in accordance with the abnormal contents, the user ID The product number of the user's liquid level meter corresponding to the product number, the part number of the part name to be replaced corresponding to the production number, the stock quantity or standard delivery date of the part of the part number, and the part number of the part to be replaced Search multiple databases that store the work procedure manual number of the corresponding repair work, the work time spent on the repair work, and the number of workers. Comprising the repair information retrieval means, retrieved the inventory or standard delivery, operating procedures number and repair information providing means for sending to the user by the communication network working time and the number of workers, as the fault recovery information,
The diagnosis logic determination means includes first failure diagnosis means for determining float submersion / decrease in internal pressure based on signals from the various sensors for failure monitoring, second failure diagnosis means for determining a float stick, and magnet A third failure diagnosis means for determining a decrease in magnetic force,
The first failure diagnosis means includes a position signal of a float magnet in the chamber, which is one of signals from the various sensors, and a liquid phase pressure of the chamber, which is one of signals from the various sensors. Based on the comparison with the actual water level signal in the liquid container based on
The second failure diagnosing means determines a float stick based on a comparison between a rate of change in unit time of the position signal and a rate of change in unit time of the actual water level signal,
The third fault diagnosing means determines a decrease in magnet magnetic force based on a repetition level change of the position signal. A magnet float type liquid level gauge fault diagnosing system. 2. The magnet float type liquid level gauge failure according to claim 1, wherein an actual water level signal is calculated with a value obtained by correcting the liquid phase pressure with a specific gravity of the liquid and used for the first and second failure diagnosis means. Diagnostic system. The actual water level signal is calculated with a value obtained by correcting the differential pressure between the liquid phase pressure of the chamber and the gas phase pressure by the specific gravity calculated based on the saturation pressure calculated from the gas phase pressure of the chamber. The magnet float type level gauge fault diagnosis system according to claim 1, wherein the fault diagnosis system is used for the first and second fault diagnosis means. Instead of the actual water level signal in the liquid container based on the liquid phase pressure of the chamber, the water level information detected from the liquid container body remotely from the magnet float type liquid level gauge is used as the actual water level signal. Item 2. The magnetic float type liquid level gauge failure diagnosis system according to Item 1.

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