JP6999532B2 - Abnormality inspection system and abnormality inspection method - Google Patents

Description

The present invention relates to an abnormality inspection system and an abnormality inspection method.

At sites such as power plants, chemical plants, and steel plants, workers may hear the operating noise of equipment to determine whether it is normal or not. However, experience is required to be able to distinguish abnormal sounds. In addition, the load on the workers is heavy because they walk around a large site and inspect by ear. Moreover, in recent years, the aging of skilled workers has progressed, and it is difficult to secure new workers. Therefore, as described in Patent Document 1, a system has been proposed in which acoustic data of a monitored object is detected by a microphone and wirelessly transmitted to a monitoring processing device at a location away from the monitored object.

Japanese Unexamined Patent Publication No. 2009-273113

In the prior art described in Patent Document 1, the monitoring processing apparatus calculates a frequency spectrum from acoustic data received from the on-site monitoring apparatus, and detects the occurrence of an abnormality in the monitored object by a neural network model (Patent Document 1, paragraph 0066). ). However, in on-site equipment such as power plants and plants, it is difficult to detect only abnormal noise generated in the monitored object because the microphone detects surrounding sounds other than the monitored object.

In addition, when a sensor device is installed in the field equipment of a plant as a so-called retrofit, it is difficult to obtain a wired power supply. Therefore, since the sensor device operates using the built-in battery as a power source, when a process with high power consumption is executed, the battery runs out immediately, the frequency of battery replacement increases, and the usability is low.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide an abnormality inspection system and an abnormality inspection method capable of detecting an abnormality of equipment to be inspected while reducing power consumption. ..

The abnormality inspection system according to one aspect of the present invention is a plurality of sensor devices that measure the physical quantity of the equipment to be inspected and analyze the measured physical quantity to create a first judgment result regarding the state of the equipment to be inspected, and each sensor. It is equipped with a data collection device that is provided so as to be able to communicate with the device and outputs a second judgment result regarding the state of the equipment to be inspected by analyzing the first judgment result from each sensor device. The data collection device is provided for each sensor. Among the devices, the judgment target sensor device for which the first judgment result indicating an abnormality is acquired is determined to be another first judgment result acquired from another predetermined sensor device arranged within a predetermined range of the judgment target sensor device. The second determination result is output by collating with the first determination result acquired from the target device.

According to the present invention, when the first determination result of the sensor device indicates an abnormality, the data acquisition device collates with the first determination result from another predetermined sensor device, so that the detection accuracy of the abnormality of the equipment to be inspected is high. Can be improved.

Layout of equipment to be inspected and wireless slave stations. An overall explanatory view of the abnormality inspection system according to the first embodiment. The flowchart which shows the whole processing of the abnormality check system which concerns on 1st Embodiment. The flowchart which shows the processing of the radio slave station which concerns on 1st Embodiment. The flowchart which shows the processing of the analysis part of a wireless slave station. A flowchart showing the processing of the wireless master station. A flowchart showing the processing of the data acquisition device. The flowchart which shows the processing of the abnormality detection part of a data collection apparatus. Explanatory drawing of the detectable range of the equipment to be inspected. An overall explanatory view of the abnormality inspection system according to the second embodiment. The flowchart which shows the whole processing of the abnormality check system which concerns on 2nd Embodiment. The flowchart which shows the processing of the radio slave station which concerns on 2nd Embodiment. The flowchart which shows the 2nd process of the wireless slave station to be determined and the 2nd process of a wireless master station. The flowchart which shows the 2nd process of a data acquisition apparatus. Data format example.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this embodiment, as described in detail below, sound (operating sound) data generated in on-site equipment such as a plant is collected, the collected sound data is analyzed, and the state of the on-site equipment is determined.

In the following description, among a plurality of wireless slave stations (sensor devices) arranged in the field, the wireless slave station to be determined may be referred to as a "determination target wireless slave station". The "other predetermined radio slave station" is a radio slave station other than the determination target radio slave station in each radio slave station, and is a radio slave station installed within a predetermined range from the determination target radio slave station. The "first determination result" is the first determination result created by the determination target radio slave station. The "other first determination result" is a first determination result created by another predetermined radio slave station.

In the present embodiment, as will be described later, a microphone 11 is provided in the wireless slave station 10, the microphone 11 is activated at regular intervals, and the operating sound of the equipment 2 to be inspected is collected. The wireless slave station 10 analyzes the collected operating sound data and transmits it to the data collecting device 30 as a first determination result indicating the state of the equipment 2 to be inspected. When the first determination result is abnormal, the data collection device 30 collates with another first determination result acquired from another predetermined radio slave station 10. If the other first determination result of the other predetermined radio slave station 10 also shows an abnormality, the first determination result from the determination target radio slave station is the sound of the environment around the inspection target equipment 2 (hereinafter, environment). It can be determined that it is a false detection due to sound). As a result, the influence of environmental sounds such as noise temporarily generated around the inspection target equipment 2 can be reduced, so that the abnormality detection accuracy of the inspection target equipment 2 can be improved.

The first embodiment will be described with reference to FIGS. 1 to 9 and 15. FIG. 1 is a layout diagram of the equipment 2 to be inspected and the wireless slave station 10. The abnormality inspection system 1 of this embodiment is applied to, for example, a power plant, a chemical plant, a steel plant, a machining plant, or the like.

The plant is provided with equipment 2 (1), 2 (2) for generating sound, such as a motor, a pump, a compressor, a turbine, a boiler, a press machine, a cutting machine, an injection molding machine, etc. (No particular distinction is made). In some cases, it may be referred to as equipment 2). At least a part of the equipment 2 that generates these sounds is a monitoring target (inspection target) by the abnormality inspection system 1. Hereinafter, the equipment 2 to be monitored is referred to as the equipment 2 to be inspected.

In the vicinity of the equipment 2 (1) and 2 (2) to be inspected, the radio slave stations 10 (1) and 10 (2) as "sensor devices" may be indicated as the radio slave stations 10 (unless otherwise specified). There is) respectively. The wireless slave station 10 (1) monitors the equipment 2 (1) to be inspected. The wireless slave station 10 (2) monitors the equipment 2 (2) to be inspected. Each radio slave station 10 may be provided in contact with the equipment to be inspected 2, or may be provided separately from the equipment 2 to be inspected. A plurality of wireless slave stations 10 may be provided in one inspection target equipment 2.

FIG. 2 is an overall explanatory view of the abnormality inspection system 1 according to the first embodiment. The abnormality check system 1 has a plurality of wireless slave stations 10, a wireless master station 20, and a data acquisition device 30.

The radio slave station 10 is a device that measures an operating sound as a "physical quantity" or a "first physical quantity" of the equipment 2 to be inspected. The wireless slave station 10 creates a first determination result regarding the state of the equipment 2 to be inspected by analyzing the measured operating sound. The wireless slave station 10 includes, for example, a microphone 11 as an example of a “sound sensor”, an analysis unit 12, a wireless communication unit 13, and a power supply unit 14. Here, the wireless slave station 10 in which the sensor function and the wireless communication function are integrated is shown, but the wireless slave station 10 may be formed by connecting the sensor function and the wireless communication function separately configured. ..

The microphone 11 collects the operating sound emitted by the equipment 2 to be inspected and outputs it as an electric signal. The electric signal output by the microphone 11 is input to the analysis unit 12. The analysis unit 12 analyzes the operating sound collected by the microphone 11 and creates a first determination result regarding the state of the equipment 2 to be inspected. The analysis unit 12 sends the first determination result to the wireless communication unit 13.

The wireless communication unit 13 is wirelessly connected to the data collection device 30 via the wireless master station 20. The wireless communication unit 13 wirelessly communicates with the wireless communication unit 21 of the wireless master station 20 to transmit the packet of the first determination result generated by the analysis unit 12 to the data collection device 30. The packet of the first determination result (described later in FIG. 15) is transmitted to the wireless master station 20 as shown in the wireless communication path L1, and further transmitted from the wireless master station 20 to the data collection device 30 as shown in the wireless communication path L2. Will be done. It should be noted that packets can be transferred by the so-called bucket brigade method by communicating between the wireless communication units 13 provided in the wireless slave stations 10 between the adjacent wireless slave stations 10.

FIG. 15 shows a configuration example of the packet D1 including the first determination result. The packet D1 stores the first determination result (in the figure, the operating sound data determination result). A header or the like storing a destination or the like is added to the packet D1 and transmitted to the wireless master station 20.

Returning to FIG. 2, the power supply unit 14 supplies the power of the built-in battery to the microphone 11, the analysis unit 12, and the wireless communication unit 13. The type of built-in battery does not matter. The power supply unit 14 receives a control signal from the power supply control unit 22, which will be described later, via the wireless communication unit 13. As a result, the power supply unit 14 starts or stops the supply of electric power.

The wireless master station 20 wirelessly communicates with a plurality of wireless slave stations 10 and transmits a packet (first determination result) from each wireless slave station 10 to the data collection device 30. The wireless master station 20 has a wireless communication unit 21 and a power supply control unit 22. The data acquisition device 30 may have the function of the wireless master station 20. In this case, the wireless slave station 10 can directly communicate with the data acquisition device 30.

The wireless communication unit 21 is connected to the wireless communication unit 13 of the wireless slave station 10 and the wireless communication unit 31 of the data collection device 30 so as to be capable of wireless communication. The power supply control unit 22 is a function of transmitting a control signal for starting or stopping the wireless slave station 10 to the power supply unit 14 of the wireless slave station 10 at a predetermined timing. The predetermined timing may be a fixed cycle or an indefinite period. Further, the predetermined timing may be set by the user.

The data collection device 30 is provided so as to be able to communicate with each radio slave station 10. The data acquisition device 30 outputs the second determination result regarding the state of the equipment 2 to be inspected by analyzing the first determination result received from each radio slave station 10. The data collection device 30 may be configured as a computer including, for example, a microprocessor, a main storage device, an auxiliary storage device, an input / output circuit, a communication circuit, a user interface device (all not shown), and the like.

The data acquisition device 30 includes a wireless communication unit 31, a position storage unit 32, a data conversion unit 33, an abnormality detection unit 34, and an output unit 35. The wireless communication unit 31 is a function of communicating with the wireless master station 20. The wireless communication unit 31 sends the packet received from the wireless communication unit 21 to the data conversion unit 33. The position storage unit 32 is a function of storing the position information of each radio slave station 10 arranged in the plant. The position storage unit 32 sends the position information of each radio slave station 10 to the data conversion unit 33.

The data conversion unit 33 is a function of extracting the first determination result from the packet of the first determination result received from each radio slave station 10. Further, the data conversion unit 33 is a function of associating and organizing the first determination result and the position information of each radio slave station. The data conversion unit 33 sends the first determination result and the position information to the abnormality detection unit 34.

The abnormality detection unit 34 is a function of analyzing the first determination result received from each radio slave station 10 and creating the second determination result regarding the state of the equipment 2 to be inspected. The abnormality detection unit 34 sends the created second determination result to the output unit 35.

The output unit 35 is a function of outputting the second determination result to, for example, a display, a printer, a voice synthesizer, or the like. The output unit 35 may notify the worker (including the administrator) of the second determination result by the abnormality detection unit 34 through an electronic means such as an e-mail. Alternatively, the output unit 35 may notify another device such as a plant control system of the second determination result by the abnormality detection unit 34.

FIG. 3 is a flowchart showing the entire processing of the abnormality inspection system 1 according to the first embodiment. The power supply control unit 22 of the wireless master station 20 monitors whether or not a predetermined timing has arrived (S1), and when the predetermined timing arrives (S1: YES), the operation of each wireless slave station 10 is started (S2). ).

Move to the processing on each radio slave station 10 side (S10). FIG. 4 is a flowchart showing the processing of each radio slave station 10 according to the first embodiment. The microphone 11 is activated by being supplied with electric power from the power supply unit 14 (S11). The microphone 11 collects the operating sound of the equipment 2 to be inspected (S12). The operating sound data collected by the microphone 11 and converted into an electric signal is input to the analysis unit 12 (S13). After the processing (S100) of the analysis unit 12 described later in FIG. 5 is completed, the wireless communication unit 13 sends a packet including the first determination result analyzed by the processing of the analysis unit 12 to the wireless communication unit 13 (S14). ).

FIG. 5 is a flowchart showing the process (S100) of the analysis unit 12 of the wireless slave station 10. The analysis unit 12 analyzes, for example, the data of the operating sound input from the microphone 11 (S101). As an analysis method, for example, it is possible to extract a preset sound intensity for each predetermined frequency and determine whether or not an abnormal sound deviating from the normal state is generated.

The analysis unit 12 confirms whether or not an abnormal noise is generated in the equipment 2 to be inspected (S103). When an abnormal noise is generated in the equipment to be inspected 2 (S103: YES), the analysis unit 12 determines that an abnormality has occurred in the equipment to be inspected (first determination result) (S104). When the operating sound of the equipment to be inspected 2 is normal (S103: NO), the analysis unit 12 determines that the equipment 2 to be inspected is normal (first determination result) (S105).

Returning to FIG. 3, the processing of the abnormality inspection system 1 moves to the processing (S20) of the wireless master station 20. FIG. 6 is a flowchart showing the processing of the wireless master station 20. When the radio master station 20 receives a packet including the first determination result from each radio slave station 10 (S21), the radio master station 20 transfers the packet including the first determination result to the data acquisition device 30 (S22). Since the header of the packet containing the first determination result contains the network address or identification information that identifies the data collection device 30 that is the final destination, the packet of the first determination result transmitted from the wireless slave station 10 Will reach the data collection device 30 even if it goes through another device on the way.

Returning to FIG. 3, the processing of the abnormality inspection system 1 moves to the processing (S30) of the data collection device 30. FIG. 7 is a flowchart showing the processing of the data collection device 30. The wireless communication unit 31 receives a packet including the first determination result from each wireless slave station 10 via the wireless master station 20 (S31). The data conversion unit 33 extracts the first determination result from the packet received by the wireless communication unit 31, and associates the first determination result with the position information (S32).

The processing of the data collecting device 30 moves to the processing of the abnormality detecting unit 34 (S300). FIG. 8 is a flowchart showing the processing of the abnormality detection unit 34 of the data collection device 30. The abnormality detection unit 34 confirms whether the first determination result of each radio slave station 10 indicates an abnormality (S301). When the abnormality detection unit 34 confirms that the first determination result of a certain radio slave station 10 indicates an abnormality (S301: YES), the abnormality detection unit 34 sets the radio slave station 10 as the determination target radio slave station 10 (S302).

The abnormality detection unit 34 confirms another predetermined radio slave station from the position information of the determination target radio slave station 10 (S303). The other predetermined wireless slave station is a wireless slave station 10 having a detectable range that overlaps with the detectable range of the determination target wireless slave station 10 among the wireless slave stations 10, and is a distance from the determination target wireless slave station 10. Is a radio slave station 10 within a predetermined distance. For example, as shown in FIG. 9, the detectable range 3 (1) of the wireless slave station 10 (1) and the detectable range 3 (2) of the wireless slave station 10 (2) overlap each other. When the radio slave station 10 (1) is the determination target radio slave station 10, the other predetermined radio slave station may be the radio slave station 10 (2).

The abnormality detection unit 34 collates another first determination result of the other predetermined radio slave station 10 (S304). When the number of other predetermined radio slave stations 10 having another first determination result indicating an abnormality is within a predetermined number (S304: YES), the abnormality detection unit 34 causes an abnormality in the equipment 2 to be inspected. It is determined that the operation is performed (second determination result). That is, when the other first determination result in the other predetermined radio slave station indicates normality, the abnormality detection unit 34 determines that an abnormality has occurred in the equipment 2 to be inspected (second determination). result).

Here, the "predetermined number" is, for example, 0. That is, when only one radio slave station 10 has detected an abnormality and none of the other predetermined radio slave stations 10 has detected an abnormality, the determination of the radio slave station 10 that has detected the abnormality is made. Estimate to be correct. When a plurality of wireless slave stations 10 around the facility 2 are detected as abnormal due to a temporary strong abnormal noise generated around the equipment 2 to be inspected, the plurality of wireless slave stations 10 may detect the abnormality. Is rather normal. However, a predetermined number may be set to a value of 1 or more. In this case, the data acquisition device 30 may determine whether or not the abnormality determination in the wireless slave station 10 is normal by considering the strength of the sound signal detected by the microphone 11.

When the abnormality detection unit 34 confirms that the first determination result of the wireless slave station 10 indicates normality (S301: NO), it is determined that the abnormal sound measured by the determination target wireless slave station 10 is an environmental sound. to decide. Further, when the number of other predetermined radio slave stations 10 indicating an abnormality exceeds a predetermined number (S304: NO), it is determined that the abnormal sound is an environmental sound. As a result, the data collection device 30 determines that the equipment 2 to be inspected is normal (second determination result) (S306). That is, when another first determination result in another predetermined radio slave station indicates an abnormality, the abnormality detection unit 34 determines that the inspection target equipment 2 is normal (second determination result).

Returning to FIG. 3, the output unit 35 outputs the second determination result created by the abnormality detection unit 34 to the output unit 35 (S3). The output destination of the second determination result is, for example, at least one of a user interface device (display, printer, etc.) connected to the data collection device 30, and another device such as a plant management system. The radio master station 20 transmits a stop signal to each radio slave station 10 to stop each radio slave station 10 (S4).

According to the present embodiment configured as described above, the data acquisition device 30 can determine whether or not the first determination result of the determination target wireless slave station 10 is an abnormal noise of the inspection target equipment 2. It is possible. Therefore, the abnormality inspection system 1 can improve the accuracy of determining the abnormality of the inspection target equipment 2. As a result, the burden on the worker who monitors the equipment 2 to be inspected can be suppressed. Further, in the abnormality inspection system 1 of the present embodiment, the wireless slave station 10 can be installed in a place where an environmental sound is generated, and the degree of freedom in installing the wireless slave station 10 can be expected to be improved.

The wireless slave station 10 can transmit the first determination result of whether or not an abnormality has occurred in the equipment 2 to be inspected to the data collection device 30. Therefore, the wireless slave station 10 can reduce the power energy required for wireless communication as compared with transmitting the operating sound data to the collecting device 30. As a result, it is possible to suppress the consumption of the built-in battery of the power supply unit 14. As a result, the frequency of battery replacement of the wireless slave station 10 can be reduced, and the equipment 2 to be inspected can be monitored for a long period of time. In the abnormality inspection system 1 of the present embodiment, the frequency of battery replacement can be reduced, so that not only the operating cost of the abnormality inspection system 1 can be reduced, but also the usability is improved.

The second embodiment will be described with reference to FIGS. 10 to 15. Since the second embodiment corresponds to a modified example of the first embodiment, the differences from the first embodiment will be mainly described. FIG. 10 is an overall explanatory view of the abnormality inspection system 1A according to the second embodiment. The abnormality check system 1A includes a radio slave station 10A, a radio master station 20, and a data collection device 30A. The wireless slave station 10A and the data acquisition device 30A are different from the wireless slave station 10 and the data acquisition device 30 in the first embodiment.

The radio slave station 10A is a device that measures the operating sound as the "first physical quantity" of the equipment to be inspected 2 and analyzes the measured operating sound to create a first determination result regarding the state of the equipment to be inspected. .. Further, the radio slave station 10A measures the vibration and temperature as the "second physical quantity" of the equipment 2 to be inspected, and indicates the vibration data and the temperature distribution data (hereinafter, "vibration temperature data" unless otherwise specified). It is a device that stores (may be).

The wireless slave station 10A includes a microphone 11 for measuring operating sound, an analysis unit 12, an acceleration (vibration) sensor 15, a data collection unit 16, an IR (infrared) sensor 17 as a "temperature sensor", and data collection. It has a unit 18, a wireless communication unit 13A, and a power supply unit 14A. The acceleration sensor 15 and the IR sensor 17 are examples of the “second sensor”. The wireless communication unit 13A and the power supply unit 14A are different from the wireless communication unit 13 and the power supply unit 14 in the first embodiment.

The acceleration sensor 15 collects the vibration generated by the equipment 2 to be inspected and outputs it as an electric signal. The electric signal output by the acceleration sensor 15 is input to the data acquisition unit 16. The data collection unit 16 is a function of storing the vibration data measured by the acceleration sensor 15. Further, the data collection unit 16 transmits vibration data to the wireless communication unit 13A when requested by the abnormality detection unit 34A, which will be described later.

The IR sensor 17 collects the temperature generated by the equipment 2 to be inspected and outputs it as an electric signal. The electric signal output from the IR sensor 17 is input to the data acquisition unit 18. The data collection unit 18 is a function of storing the temperature distribution data measured by the IR sensor 17. Further, the data collection unit 18 transmits the temperature distribution data to the wireless communication unit 13A when requested by the abnormality detection unit 34A described later. The "temperature sensor" is not limited to the IR sensor, and examples thereof include a thermistor, a thermocouple, and a platinum side temperature resistor (Pt100).

The wireless communication unit 13A is a function of transmitting a packet including the first determination result generated by the analysis unit 12 to the data collection device 30A. Further, the wireless communication unit 13A is a function of transmitting a packet including vibration data stored in the data collection unit 16 to the data collection device 30A. Further, the wireless communication unit 13A is a function of transmitting a packet including the temperature distribution data stored in the data collection unit 18 to the data collection device 30A.

FIG. 15 shows a configuration example of packets D2, D3, and D4. The packet D2 stores the vibration data measured by the accelerometer. Packet D3 stores the temperature distribution data measured by the IR sensor. A header or the like storing a destination or the like is added to the packets D2 and D3, and the packet D2 and D3 are transmitted to the wireless master station 20. The packet to be transmitted may be a packet D4 in which the vibration data of the packet D2 and the temperature distribution data of the packet D3 are combined.

Returning to FIG. 10, the power supply unit 14A supplies the power of the built-in battery to the microphone 11, the analysis unit 12, the wireless communication unit 13A, the acceleration sensor 15, the data collection unit 16, the IR (infrared) sensor 17, and the data collection unit 18. .. The type of built-in battery does not matter. The power supply unit 14A starts or stops power supply by receiving a control signal from the power supply control unit 22 via the wireless communication unit 13A.

The data acquisition device 30A is provided so as to be able to communicate with each radio slave station 10A. Further, the data acquisition device 30A is a function of creating a second determination result regarding the state of the equipment 2 to be inspected by analyzing the first determination result received from each radio slave station 10A. Further, the data acquisition device 30A is a function of outputting the third determination result by analyzing the vibration temperature data of the determination target radio slave station 10A when the second determination result indicates an abnormality. The data collection device 30A may be configured as a computer including, for example, a microprocessor, a main storage device, an auxiliary storage device, an input / output circuit, a communication circuit, a user interface device (all not shown), and the like.

The data acquisition device 30A includes a wireless communication unit 31, a position storage unit 32, a data conversion unit 33A, an abnormality detection unit 34A, and an output unit 35. The data conversion unit 33A and the abnormality detection unit 34A are different from the data conversion unit 33 and the abnormality detection unit 34 in the first embodiment.

The data conversion unit 33A is a function of extracting the first determination result from the packet of the first determination result received from each radio slave station 10A. In addition, the data conversion unit 33A is a function of associating the first determination result with the position information of each radio slave station 10A. Further, the data conversion unit 33A is a function of extracting vibration temperature data from packets of vibration data and temperature distribution data received from each radio slave station 10A and restoring the data. The data conversion unit 33A transmits the first determination result and the vibration temperature data to the abnormality detection unit 34A.

The abnormality detection unit 34A is a function that analyzes the first determination result received from the radio slave station 10A and creates the second determination result regarding the state of the equipment 2 to be inspected. Further, the abnormality detection unit 34A is a function of creating a third determination result by analyzing the vibration temperature data of the determination target radio slave station 10A when the second determination result indicates an abnormality. The abnormality detection unit 34A can communicate with the data collection units 16 and 18 via the wireless communication unit 31. The abnormality detection unit 34A transmits the third determination result to the output unit 35.

FIG. 11 is a flowchart showing the entire processing of the abnormality inspection system 1A according to the second embodiment. Since steps S1, S2, S20, and S30 in the process of the wireless slave station 10A of FIG. 11 are the same as the process of the wireless slave station 10 described in the description of FIG. 4, detailed description thereof will be omitted.

After the wireless slave station 10A is activated (S2), the processing of the abnormality check system 1A moves to the processing of the wireless slave station 10A (S10A). FIG. 12 is a flowchart showing the processing of the radio slave station 10A according to the second embodiment. Since steps S13, S100, and S14 in the process of the wireless slave station 10A of FIG. 12 are the same as the process of the wireless slave station 10 described with reference to FIG. 4, detailed description thereof will be omitted.

The microphone 11, the acceleration sensor 15, and the IR sensor 17 are activated when the power supply unit 14A is turned on (S11A). The microphone 11 collects the operating sound of the equipment 2 to be inspected. Further, the acceleration sensor 15 collects the vibration of the equipment 2 to be inspected. Further, the IR sensor 17 collects the temperature of the equipment 2 to be inspected (S12A). The vibration data collected by the acceleration sensor 15 and converted into an electric signal is stored in the data acquisition unit 16. Further, the temperature distribution data collected by the IR sensor 17 and converted into an electric signal is stored in the data acquisition unit 18 (S15).

Returning to FIG. 11, by performing the processing S20 of the wireless master station 20 and the processing S30 of the data collecting device 30A, the data collecting device 30A determines the abnormality of the equipment 2 to be inspected (second determination result). When the second determination result indicates an abnormality (S5: YES), the abnormality detection unit 34A transfers the vibration temperature data to the data acquisition units 16 and 18 of the determination target wireless slave station 10A via the wireless communication unit 31. Make a request (S6). When the second determination result indicates normality (S5: NO), the radio master station 20 stops each radio slave station 10A (S4).

The process of the abnormality check system 1A moves to the second process of the wireless slave station 10 to be determined (S40). FIG. 13 is a flowchart showing the second process of the wireless slave station 10A to be determined and the second process of the wireless master station 20. The determination target radio slave station 10A receives the request signal of the vibration temperature data transmitted from the data acquisition device 30A (S41). The data collection units 16 and 18 send a packet containing the vibration temperature data to the wireless communication unit 13 (S42).

The processing of the abnormality check system 1A moves to the processing of the wireless master station 20 (S50). The radio master station 20 acquires a packet including vibration temperature data from the determination target radio slave station 10A (S51). The wireless master station 20 transfers the packet including the vibration temperature data to the data acquisition device 30A (S52). Since the header of the packet containing the vibration temperature data contains the network address or identification information that identifies the data collection device 30A that is the final destination, the packet of the vibration temperature data transmitted from the determination target radio slave station 10A. Will reach the data collection device 30A even if it goes through another device on the way.

Returning to FIG. 11, the process of the abnormality check system 1A moves to the second process of the data acquisition device 30A (S60). FIG. 14 is a flowchart showing the second process of the data acquisition device 30A. The wireless communication unit 31 receives a packet including vibration temperature data from the wireless master station 20 (S61). The data conversion unit takes out vibration temperature data from the received packet and restores it (S62).

The abnormality detection unit 34A analyzes the vibration temperature data (S63). In the analysis method, for example, the vibration data measured by the determination target radio slave station 10A is collated with the vibration data in the normal state. As a result, the analysis method includes determining whether or not an abnormal vibration that deviates from the normal state is generated in the equipment 2 to be inspected. Further, in the analysis method, for example, the temperature distribution data measured by the determination target radio slave station 10A is collated with the temperature distribution data in the normal state. As a result, the analysis method includes determining whether or not an abnormal temperature deviating from the normal temperature is generated in the inspection target equipment 2.

The abnormality detection unit 34A confirms whether or not an abnormality has occurred in the equipment 2 to be inspected (S64). When the analysis result of the vibration temperature data indicates an abnormality (S64: YES), the abnormality detection unit 34A determines that an abnormality has occurred in the equipment 2 to be inspected (third determination result) (S65). When the analysis result of the vibration temperature data shows a normal value (S64: NO), the abnormality detection unit 34A determines that the abnormal sound measured by the radio slave station 10 is an environmental sound. As a result, the abnormality detection unit 34A determines that the equipment 2 to be inspected is normal (third determination result) (S66). The output unit 35 outputs the third determination result (S67). Returning to FIG. 11, the radio master station 20 transmits a stop signal to each radio slave station 10A to stop each radio slave station 10A (S4).

This embodiment configured in this way also has the same effect as that of the first embodiment. Further, the abnormality inspection system 1A in this embodiment creates a third determination result using a plurality of physical quantities such as operating sound data, vibration data, and temperature distribution data. As a result, the abnormality inspection system 1A can further improve the accuracy of detecting the abnormality of the inspection target equipment 2.

The data acquisition device 30 can be realized by either a so-called cloud service or on-premises. In the case of the cloud service, the data collecting device 30 on the network can monitor the sensor network system (configuration of the wireless slave station 10 and the wireless master station 20) distributed in the plants in each place. When operating on-premises, the data acquisition device 30 is installed in the same plant as the sensor network system. When the abnormal noise inspection system is realized as a cloud service, it is possible to manage the equipment status of a plurality of plants operated by different operators.

The present invention is not limited to the above-described embodiment. Those skilled in the art can make various additions and changes within the scope of the present invention. In the above-described embodiment, the configuration is not limited to the configuration example shown in the attached drawings. The configuration and processing method of the embodiment can be appropriately changed within the range of achieving the object of the present invention.

Further, each component of the present invention can be arbitrarily selected, and the invention including the selected configuration is also included in the present invention. Further, the configurations described in the claims can be combined in addition to the combinations specified in the claims.

1,1A Abnormality inspection system 2 (1), 2 (2), 2, 2A Equipment to be inspected 10 (1), 10 (2), 10, 10A Wireless slave unit 20 Wireless master unit 30, 30A Data collection device

Claims (6)

An abnormality inspection system that determines the state of the equipment to be inspected based on the physical quantity measured from the equipment to be inspected.
A plurality of sensor devices that measure the physical quantity of the equipment to be inspected and analyze the measured physical quantity to create a first determination result regarding the state of the equipment to be inspected.
It is provided with a data acquisition device that is provided so as to be communicable with each of the sensor devices and outputs a second determination result regarding the state of the equipment to be inspected by analyzing the first determination result from each of the sensor devices.
The data collecting device acquires from other predetermined sensor devices arranged within a predetermined range of the determination target sensor device for the determination target sensor device for which the first determination result indicating an abnormality is acquired among the sensor devices. By collating the other first determination result obtained with the first determination result acquired from the determination target sensor device, the second determination result is output.
The other predetermined sensor device is a sensor device having a detectable range that overlaps with the detectable range of the determination target sensor device among the above sensor devices, and the distance from the determination target sensor device is within a predetermined distance. A sensor device ,
Abnormality inspection system. Each sensor device has a first sensor for measuring a first physical quantity and at least one second sensor for measuring a second physical quantity different from the first physical quantity.
Each of the sensor devices transmits the first determination result regarding the state of the equipment to be inspected to the data collection device by analyzing the first physical quantity measured by the first sensor.
The data collecting device acquires from other predetermined sensor devices arranged within a predetermined range of the determination target sensor device for the determination target sensor device for which the first determination result indicating an abnormality is acquired among the sensor devices. The other first determination result obtained is collated with the first determination result acquired from the determination target sensor device, and the result is collated.
The data collecting device is based on a collation result between the first determination result acquired from the determination target sensor device and the other first determination result acquired from the other predetermined sensor device. When the determination result is affirmed, the data regarding the second physical quantity is acquired from the second sensor of the determination target sensor device.
The abnormality inspection system according to claim 1. The first sensor is a sound sensor.
The second sensor is at least one of an acceleration sensor and a temperature sensor.
The abnormality inspection system according to claim 2 . Each of the sensor devices is operated by a built-in battery.
The abnormality inspection system according to claim 1. Each of the sensor devices is wirelessly connected to the data acquisition device via a wireless master station.
The abnormality inspection system according to claim 1. It is an abnormality inspection method that determines the state of the equipment to be inspected based on the physical quantity measured from the equipment to be inspected.
A plurality of sensor devices that measure the physical quantity of the equipment to be inspected and analyze the measured physical quantity transmit the first determination result regarding the state of the equipment to be inspected to the data collection device.
The data collecting device determines the detectable range of each of the sensor devices that overlaps with the detectable range of the determination target sensor device for the determination target sensor device for which the first determination result indicating an abnormality is acquired. The other first determination result acquired from another predetermined sensor device that has a sensor device and the distance from the determination target sensor device is within a predetermined distance, and the first determination acquired from the determination target sensor device. An abnormality check method that outputs the second judgment result by collating with the result.

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