JPH01286694A - Fault diagnosing device for plant dispersion control system - Google Patents

Abstract

PURPOSE:To support a maintainer and to diagnose a fault in a plant dispersion control system by roughly diagnosing the fault in the distribution control system by a central diagnosing device with a remote diagnosis and diagnosing the fault by a movable auxiliary diagnosing device, in which necessary diagnostic knowledge is stored, in a field. CONSTITUTION:Fault diagnosing knowledge for the whole of a dispersion control system 3 is stored in a knowledge base 12 of a central diagnosing device 1. When faults occur in field controllers 32-37 of the system 3, the device 1 starts a fault diagnosis by either an abnormality detecting signal from a process computer 31 or a manual request from an interacting means 13. The device 1 takes in plant data from the system 3 and state data from the field controllers 32-37 by a data input means 15 and stores the data in a taking in plant data base 14. A diagnosis processing means 11 collects information necessary for the fault diagnosis from the data base 14 and the means 13 and executes the fault diagnosis. In order to execute a further detailed diagnosis, the diagnostic knowledge fetched from a diagnostic knowledge selecting means 16 is transferred to an auxiliary diagnosing device 2 and stored in a storing means 22, and the detailed diagnosis is executed in the field.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a diagnostic device for diagnosing a failure of a field control device in a distributed control system of a plant.

In particular, the present invention relates to a diagnostic device suitable for maintenance personnel to easily carry out the above-mentioned tests when manual tests are required in the field for detailed failure diagnosis.

[Prior Art] As described in Japanese Patent Application Laid-Open No. 129945/1982, a conventional diagnostic device connects a host computer and an on-site control device or a diagnostic device through a communication line, and is controlled by a diagnostic program in the host. The method used was to send a diagnostic command to the device or diagnostic device and collect status information of the device to be diagnosed.

[Problems to be Solved by the Invention] When applying the above-mentioned conventional technology to a distributed control system of a plant, 1. Diagnostic communication lines connecting the host computer that executes diagnosis and the on-site control device must be installed at various locations. The problem arises that it must be done. Further, although the method of the prior art assumes that information used for diagnosis is automatically collected, there is a limit to the information that can be automatically collected.

In other words, when narrowing down the failure location to a maintainable unit such as a printed circuit board, depending on the nature of the failure, it may be necessary to proceed with the diagnosis while performing manual operations such as replacing the printed circuit board or turning the power back on to the failed device. , such information cannot be collected automatically.Therefore, the method described above, which assumes that all diagnostic data is collected automatically, may not be able to sufficiently narrow down the failure location due to such limitations. Of course it can happen.

The present invention has been made in order to solve the above-mentioned problems, and supports maintenance personnel when it becomes necessary to manually test the diagnosis target on site for detailed failure diagnosis. The purpose of the present invention is to provide a diagnostic device for a distributed control system that enables the diagnosis of distributed control systems.

[Means for Solving the Problems] In order to achieve the above object, the present invention provides remote fault diagnosis based on a knowledge base regarding fault diagnosis for the entire plant distributed control system (including individual field control devices). It consists of a central diagnostic device that executes the test, and an auxiliary diagnostic device that is used on-site separately from the central diagnostic device.This allows the central diagnostic device to perform a general diagnosis of the entire distributed system.

For failures where the failure location cannot be narrowed down to maintainable units, the diagnostic knowledge necessary for detailed diagnosis is stored from the central diagnostic device to the auxiliary diagnostic device, and this auxiliary diagnostic device is used to identify the failed device (faulty on-site control This system allows detailed diagnosis to be performed at the site where the equipment is installed.

[Function] The knowledge base of the central diagnostic equipment includes diagnostic knowledge that uses information collected online from the distributed control system and information collected in an interactive format, as well as manual operations of on-site equipment such as replacing boards and turning on the power again. Diagnostic knowledge using the results of is stored.

When an error occurs in one distributed control system, the central diagnostic device uses the plant data and operating status information of each control device that are input to the central diagnostic device interactively or online from the distributed control system, and performs failure diagnosis based on the above knowledge base. Execute the process and identify the failure location within the range of information obtained. As a result of this diagnosis, we were unable to narrow down the failure location to a maintainable unit.
If more detailed diagnosis is required, the knowledge used for detailed diagnosis of previous diagnosis results, such as diagnosis knowledge using field data, is extracted from the above knowledge base of the central diagnosis device and used in the auxiliary diagnosis device. Store in knowledge base.

The auxiliary diagnostic device is then separated from the central diagnostic device and moved to the location where the field control device to be diagnosed is installed.
Based on detailed diagnostic knowledge stored in the knowledge base of the auxiliary diagnostic device, instructions for testing the on-site control device that is subject to one diagnosis are displayed to the maintenance personnel, and the results of the tests performed by the maintenance personnel are displayed accordingly. Run detailed diagnostics as you type.

[Example code] An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram of a diagnostic apparatus of the present invention. In FIG. 1, 1 is a central diagnostic device, 2 is an auxiliary diagnostic device, and 3 is a distributed control system of a plant to be diagnosed. The plant distributed control system 3 is constructed by interconnecting a plurality of control devices 32 to 37 and a process computer 31, which are distributed and installed at the plant site, through a transmission line 3o. The process computer 31 receives plant data from the on-site control devices 32 to 37 via the transmission line 30 and monitors the operating state of the plant in general.

The central control device 1 is the field control device 3 of the distributed control system 3
2 to 37, for example, in a central control room where plant operation is controlled, and connected to the distributed control system 3 via a connecting cable 10. Further, the central diagnostic device 1 and the auxiliary diagnostic device 2 are also connected by a connecting connector 17.24 and a connecting cable 20.

In the central diagnostic device I, 11 is a diagnostic processing means.

Reference numeral 12 denotes a knowledge base that stores knowledge related to diagnosis.

Reference numeral 13 denotes an interactive means, which has an information display function such as a CRT and an information input function such as a keyboard.

14 is a plant database that stores plant data and status data of the distributed control system 3; 15 is a data input means for taking in data from the distributed control system 3; and 16 is a diagnostic knowledge selection output means.

Further, in the auxiliary diagnostic device 3, 21 is a diagnostic processing means;
22 is a storage means for storing diagnostic knowledge, and 23 is an interaction means.

The functions of each part will be explained below. The knowledge base 12 of the central diagnostic device 1 stores diagnostic knowledge regarding failure diagnosis of the entire distributed control system 3. This diagnostic knowledge is stored in the plant database 14 and the dialogue means 13.
In addition to diagnostic knowledge using information obtained from, data and failure bags that can only be obtained on site! ! Also includes diagnostic knowledge using the results of manual testing of (failed field control equipment).

When a failure occurs in the field control devices 32 to 37 of the distributed control system 3, the central diagnostic bag N1 starts failure diagnosis of the distributed control system 3 in response to an abnormality detection signal from the process computer 31 or a manual request from the interaction means 13. . The central diagnostic device 1 first receives plant data and field control devices 32 to 32 from the distributed control system 3 using the data input means 15.
37 status data are imported and the plant database 1 is created.
Store in 4. The diagnostic processing means 11 is based on diagnostic knowledge in the knowledge base 12 using information obtained from the plant database 14 and the interaction means 13.

Information necessary for diagnosis is collected from the plant database 14 or the interaction means 13, and a failure diagnosis is performed.

As a result, the fault location identified within the range of this knowledge is output to the dialog means 13 as a diagnosis result.

At this time, depending on the failure details, the failure location may not be narrowed down to a repairable unit, and in this case, the failure location may not be narrowed down to a repairable unit.
Multiple failure candidates are output as diagnosis results.

The diagnostic knowledge selection output means 16 outputs the diagnostic knowledge necessary to carry out a more detailed diagnosis, that is, data that can only be obtained on-site and the results of manual testing of a failed device, based on the diagnostic results output by the diagnostic processing means 11. 1 Diagnostic knowledge selection output means 1 for extracting diagnostic knowledge, etc. to be used from the knowledge base 12
The diagnostic knowledge retrieved from 6 is transferred from the central diagnostic device 1 to the auxiliary diagnostic device 2 via the connecting cable 20 and stored in the storage means 22 of the auxiliary diagnostic device 2.

After the diagnostic knowledge has been stored in the storage means 22 of the auxiliary diagnostic device 2, the auxiliary diagnostic device 2 is separated from the central diagnostic device 1 by removing the connecting cable 20. Thereafter, the auxiliary diagnostic device 2 is moved to the installation location of the failed device, and detailed diagnosis is performed by the auxiliary diagnostic device 2 at the site. That is, the diagnostic processing means 21 of the auxiliary diagnostic device 2 displays the necessary test and data collection procedures and methods on the dialog means 23 based on the diagnostic knowledge in the storage means 22. The maintenance worker tests the on-site control device to be diagnosed according to these instructions, and inputs the results through the dialog means 23.The diagnosis processing means 21 thus proceeds with the diagnosis in an interactive manner with the maintenance worker using the dialog means 23. ,
Execute detailed failure diagnosis for on-site control equipment and narrow down the failure location to maintainable units. This diagnosis result is displayed on the dialog means 23.

FIG. 2 is a diagram showing an example of the knowledge base 12.

41 is a rule storage section that stores knowledge related to failure diagnosis; 1 diagnosis knowledge is written in the rule format (IF condition section, THEN conclusion section); 0 condition section stores data in the plant database 14 and predetermined reference values; Comparison with Dialogue Means 1
Determination of the response results from 3, determination of intermediate conclusions of the previous inferences, etc. are described. Further, the conclusion part describes the conclusion when the condition part is satisfied, the output message to the dialogue means 13, the response input from the dialogue means 13, etc. 42
is a working memory unit, which stores intermediate results of inference, input information from dialogue means, etc.

FIG. 3 is a flowchart showing the processing procedure in the diagnostic processing means 11, and 81 to s4 represent processing steps.
In processing steps 81 to S2, it is determined whether the condition part of each piece of knowledge in the rule storage unit 41 of the knowledge base 12 holds true, and one piece of knowledge for which the condition part holds is taken out, that is, according to the description content of the condition part of each piece of knowledge. With reference to the contents of the working storage unit 42 of the plant database 14 and knowledge base 12, it is possible to compare plant data with reference values, determine response results from the dialog means 13, or determine intermediate conclusions of previous inferences, etc. In step S3, the execution condition part takes out one piece of knowledge that holds true, and in accordance with the description of the conclusion part of the knowledge that holds true, the condition part stores the intermediate conclusion in the working storage part 42,
The receiver receives the response to the message outputted to the dialogue means 13 and executes processing such as storing it in the working memory section 42.

Here, if the conclusion section describes an operation that is impossible at the location where the central diagnostic device 1 is installed, such as inputting test results of the field control device, execution of this knowledge is skipped.

The above processing is repeatedly executed, and the diagnostic processing ends when there is no longer any knowledge that the conditional part is satisfied. At this time, processing step s4 outputs the conclusion obtained by the previous inferences to the dialog means 13 as the final conclusion.

As described above, the diagnostic processing means 11 of the diagnostic device 1 diagnoses the failure location within the range of information obtained at the location where the central diagnostic device 1 is installed.

FIG. 4 is a flowchart showing the processing procedure of the diagnostic knowledge selection output means 16, in which sll to s15 represent processing steps. Diagnostic knowledge for further detailed diagnosis is selected and extracted from the knowledge base 12 as a starting point, and is executed in the following one procedure.

First, in processing step 811, all diagnostic knowledge having the conclusion obtained by the diagnostic processing means 11 in the condition part is extracted from the knowledge base 12 and stored in a working file (not shown) in the diagnostic knowledge selection output means 16. Next, processing step s1
2, one piece of diagnostic knowledge is extracted from the work file and output to the auxiliary diagnostic device i2. In processing step s13, all the diagnostic knowledge whose condition part contains the information of the conclusion part of the diagnostic knowledge extracted in processing step s12 is extracted from the knowledge base 12, and is additionally stored in the work file.0For example, the diagnosis extracted in processing step s12 is If the rTHEN board A is faulty on the board in the conclusion part of the knowledge, the diagnostic knowledge that is written as "rIF board A failure" in the condition part is extracted from the knowledge base 12, and rTHEN is written in the conclusion part.
PRINT “Replace substrate A with normal crystal”; INPUT
If it is written as "Normal after board A replacement"
INPUT means input the input information x (yes or no) from the dialog means 13, which is the maintenance personnel's response to the message "...") 1 rIF in the condition part. Normal after replacing board A Y" or rIF Normal after replacing board A NJ (Y is yes,
The diagnostic knowledge described as "N" means "no" and was input by the maintenance personnel as a response result from the dialog means 13 is retrieved from the knowledge base 12. In processing step s14, from the work file to processing step s12.
Delete the diagnostic knowledge retrieved with . Processing step s12
Processing step s14 is repeated until the work file becomes empty.

Through the above processing procedure, diagnostic knowledge necessary for detailed diagnosis of the conclusion obtained by the diagnostic processing means 11 is extracted from the knowledge base 12 of the central diagnostic apparatus 1 and stored in the storage means 22 of the auxiliary theory diagnostic apparatus t2. The diagnostic processing means 21 of the auxiliary diagnostic apparatus 2 uses the diagnostic knowledge stored in the storage means 22 to execute diagnostic processing in the same procedure as the diagnostic processing means 11 of the central diagnostic apparatus 1.

FIG. 5 shows another embodiment of the diagnostic device of the present invention.

In Figure 5, codes 1-3.11-16.21.23
shows the same thing as in Figure 1. 40 is a removable storage medium such as a floppy disk, a magnetic tape, or an optical disk, and 18 and 25 are drive devices for the removable storage medium.

Central diagnostic equipment! When the diagnosis is executed by l, the storage medium 40 is the driving bag of the central diagnostic device 1! ! The zero diagnostic knowledge selection output hand 16 attached to the drive device 18 stores the diagnostic knowledge retrieved from the knowledge base 12 in the storage medium 40 attached to the drive device 18 . After the diagnosis by the central diagnostic device 1 is completed, the storage medium 4o is removed from the drive device 18 of the diagnostic device 1 and attached to the drive bag N25 of the auxiliary diagnostic device 2.

Thereby, the diagnostic knowledge in the knowledge base 12 of the central diagnostic device 1 can be transferred to the auxiliary diagnostic device 2 without connecting the diagnostic device 1 and the auxiliary diagnostic device 2.

FIG. 6 shows another embodiment of the central diagnostic device 1. In FIG.

In FIG. 6, numerals 11 to 16 indicate the same parts as in FIG. Reference numeral 19 denotes a maintenance database, which stores information useful for testing and maintenance of the field control device, such as device implementation diagrams and circuit diagrams.

When the diagnostic knowledge selection output means 16 extracts the diagnostic knowledge necessary for detailed diagnosis of the field control device from the knowledge base 12, the diagnostic knowledge selection output means 16 outputs maintenance information related to this diagnostic knowledge to the maintenance database 19.
0 To retrieve the maintenance information related to the diagnostic knowledge, write the identification number of the maintenance information together with the instructions for testing the on-site control device in the conclusion part of the diagnostic knowledge. This can be easily achieved by keeping the

As a result, if the auxiliary diagnostic device 2 is equipped with the function of reading and displaying maintenance information, maintenance personnel can obtain detailed information for maintenance at the location where the on-site control device is installed, improving the efficiency of maintenance inspection work. I can figure it out.

In the embodiments described above, the auxiliary diagnostic device 2 has shown an example in which diagnosis is performed in an interactive manner with maintenance personnel, but the auxiliary diagnostic device w12 is equipped with a test means,
It is also possible to automatically collect test results. In this case, the test data may include memory dump information of the device to be diagnosed (information that outputs all memory contents of the computer of the device to be diagnosed), signal waveforms at multiple locations, etc., and in addition to handling a large amount of data, the analysis procedure is also required. Although it is complicated, it becomes possible as memory devices become smaller and faster.

FIG. 7 shows an embodiment of an auxiliary diagnostic device 2 having such a test means. In FIG. 7, 21 to 23 are the same as in FIG. 1, 25 is a test means, 26 is a test data analysis means, and 27 is a test data storage section. Here, the operation will be explained by taking as an example the case where signal waveforms at multiple locations of a device to be diagnosed are analyzed as a test content. At this time, if there is a signal waveform analysis instruction in the conclusion part of the diagnostic knowledge,
The waveform ants location is displayed on the dialog means 23. The maintenance worker connects the observation probe P1''Pn to a predetermined location of the device to be diagnosed according to the instructions from the dialogue means 23, and inputs from the dialogue means 23 that the connection has been completed. 01 including the measurement command, and sends the analysis procedure C2 to the test data analysis means 26.The test means 25 samples and takes in the signal voltage from the observation probes P1 to Pn for a certain period of time, and stores the 1m measurement data in the test data storage section 2.
Store in 7. The test data analysis means 26 reads the observation data from the test data storage section 27, and the diagnostic processing means 21
The data is analyzed according to the analysis procedure sent in advance from the diagnostic processing means 21, and the results are sent to the diagnostic processing means 21.

The above measurement method and analysis procedure are handled as maintenance information described in the embodiment shown in FIG.
It is taken out and stored in the storage means 22.

[Effects of the Invention] As described above, according to the present invention, a general diagnosis of a distributed control system is performed by remote diagnosis using a central diagnosis device,
For detailed diagnosis, including tests and maintenance work on on-site control equipment, an auxiliary diagnostic device that stores the necessary diagnostic knowledge is carried to the location where the equipment to be diagnosed is installed. There is no need for a communication line to be connected to the control device, and the auxiliary diagnostic device can show testing and maintenance work procedures, so even less-skilled maintenance personnel can perform maintenance diagnostics on the same level as experts. This makes it possible to improve the efficiency of maintenance and diagnosis work for distributed control systems.

Furthermore, since necessary knowledge is selected from the knowledge base of the central diagnostic device and stored in the knowledge base of the auxiliary diagnostic device, there is no need to create a special knowledge base for the auxiliary diagnostic device in advance.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a configuration diagram of an embodiment of the diagnostic apparatus of the present invention. FIG. 2 is an illustration of the knowledge base, FIG. 3 is a flowchart of the diagnostic processing means, FIG. 4 is a flowchart of the diagnostic knowledge selection means, and FIG. 5 is a diagram showing another embodiment of the diagnostic apparatus of the present invention. , FIG. 6 is a diagram showing another embodiment of the central diagnostic device,
FIG. 7 is a diagram showing another embodiment of the auxiliary diagnostic device. 1...Central diagnostic device 2...Auxiliary diagnostic device 3...Distributed control system 11.21...Diagnostic processing means 12...Knowledge base 16...Diagnostic knowledge selection output means FIG.

Claims (1)

[Scope of Claims] 1. A failure diagnosis device for a plant distributed control system that monitors and controls a plant using a plurality of on-site control devices, comprising:
It consists of a central diagnostic device and an auxiliary diagnostic device that is separately movable to the installation location of the field control device.The central diagnostic device has a knowledge base for fault diagnosis for multiple field control devices, and a plant The system includes a diagnostic processing means for performing a general fault diagnosis on the entire distributed control system, and a diagnostic knowledge selection output means for extracting diagnostic knowledge necessary for detailed diagnosis of the diagnosis result of the diagnostic processing means from the knowledge base. , the auxiliary diagnostic device includes a storage device for storing the diagnostic knowledge retrieved by the diagnostic knowledge selection output device, and a storage device that receives the test results of the field control device based on the diagnostic knowledge stored in the storage device, and 1. A failure diagnosis device for a plant distributed control system, comprising a diagnostic processing means for performing detailed diagnosis of a control device. 2. The diagnostic knowledge retrieved by the diagnostic knowledge selection output means is transferred to the storage means in the auxiliary diagnostic device by transfer via the electrical connection means detachably connected between the central diagnostic device and the auxiliary diagnostic device. 2. The fault diagnosis device for a plant distributed control system according to claim 1, wherein the fault diagnosis device stores information. 3. The diagnostic knowledge extracted by the diagnostic knowledge selection output means is stored in a removable storage medium, and the reproduced output from this storage medium is stored in the storage means in the auxiliary diagnostic device. Fault diagnosis equipment for plant distributed control systems. 4. The central diagnostic device has a maintenance information storage means and its retrieval means, the retrieved maintenance information is stored in the storage means in the auxiliary diagnostic device, and the auxiliary diagnostic device displays the maintenance information together with diagnostic instructions. A fault diagnosis device for a Platonic distributed control system according to claim 1, 2 or 3, wherein the device is configured as follows. 5. The auxiliary diagnostic device is further provided with means for automatically performing a test of the field control device and an analysis of the test data based on the diagnostic knowledge stored in the storage means in the auxiliary diagnostic device. A failure diagnosis device for a Platonic distributed control system according to 2, 3 or 4. 6. The early diagnosis knowledge selection output means uses a knowledge selection function to retrieve all knowledge having a specified conclusion in the condition part from the knowledge base that stores a plurality of pieces of knowledge consisting of a condition part and a conclusion part. 6. The fault diagnosis device for a Platonic distributed control system according to claim 1, wherein all knowledge connected to the conclusion part and the condition part is taken out in a chain, starting from the conclusion.