JPH07306712A - Maintenance support system of digital controller - Google Patents

Abstract

PURPOSE:To provide the maintenance support device of the digital controller which has fault analysis and recovery guidance data and also identifies a fault place and generates a substrate replacement instruction by automatically analyzing fault information data. CONSTITUTION:This device consists of a diagnostic signal decoding device 18 which decodes the diagnostic signal 16 of the digital controller 1 into fault information, an abnormality factor decoding device 20 which holds, for example, a fault tree data base, an abnormality factor analyzing device 22 which outputs abnormal place recognition data 26, an abnormal place identification device 27 which outputs abnormal place identification data 32, an abnormal place replacement condition input device 36 which outputs abnormal place replacement condition data 42, and an abnormal place replacement guidance device 43 which indicates the abnormal place replacement guidance data 47 on a display device 48, etc.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to maintenance work support in a plant that employs digital control in various plants such as power generation, iron making, chemicals, etc., and more particularly to a digital control system for supporting failure recovery of various substrates in a digital controller. The present invention relates to a maintenance support device for a control device.

[0002]

2. Description of the Related Art Recent power plants, iron making, paper making, machine making,
In various plants such as chemical factories, control by a distributed control system in which a microprocessor, an optical multiplex transmission system, and a digital control device to which a diagnostic technique is applied has been largely introduced has become mainstream.

Stable operation of these plants is becoming more and more important by maintaining and improving the quality and cost performance of products from the plants, and specifically, plants such as power plants. Is to improve the operating rate of. Therefore, for this purpose, it is necessary to promptly restore the failed portion when the digital control device fails.

The perspective view of FIG. 8 shows a typical example of a conventional digital control device. The digital control device 1 is generally formed in a cabinet, and a power supply device 2 is provided on the upper part thereof.
Then, the CPU board 3, the memory board 4, the diagnostic information board 5, the battery board 6, and the transmission control board 7 are loaded in the next stage,
A plurality of input / output boards 8 are arranged on the lower stage thereof.

In each plant, a large number of the digital control devices 1 as described above are connected by an optical multiplex transmission network (not shown) to perform distributed control, and the number reaches 20 to 100 units at a power plant, for example.

When the number of units of the digital control device 1 is large, the power supply device 2, the CPU board 3, the memory board 4, the diagnostic information board 5, the battery board 6, the transmission control board 7, the input / output board 8, etc., which are the constituent elements, are included. The number will be huge, therefore
The probability of failure also increases.

Further, even if the same substrate is used, the usage conditions and purposes are different, and therefore the countermeasures are different each time a failure occurs, and it is a heavy burden on maintenance personnel to promptly respond to a failure for stable operation of the plant. ing.

Since the occurrence of a failure in the digital controller 1 used in a system or equipment particularly important for a plant needs to be promptly dealt with and recovered in a short time, it is necessary to identify the failure and determine the board replacement location. It is an important key for maintenance work.

The failure information of the conventional digital control device 1 is the code signal (A to Z or 1,0) from the viewpoint of reducing the memory capacity by using the information by the diagnostic function on the diagnostic information board 5.
It is difficult for anyone who has specialized knowledge to decipher this because it is memorized by the combination).

Therefore, by any chance, the digital controller 1
When a failure occurs, the measures shown in the work process diagram of FIG. 9 have been taken. In this FIG. 9, the horizontal axis represents the time from the occurrence of a failure to the restoration, and the vertical axis represents the work element (density × man-hours). The solid line 9 indicates the site work by the operator or maintenance staff in the plant, etc. The work of the support units by experts in expertise and design, etc. is indicated by dashed line 10.

When a failure occurs in the digital control device 1, an operator at the site checks the status of the entire plant and the equipment at the time of the failure with an alarm display window, a trip log of a computer, etc. 11
After that, the display contents of the diagnostic information board 5 are confirmed and the memory information is collected.

At the same time, the support unit in the manufacturing plant or the like is informed of the situation to collect the necessary information and the additional information, pass the data to the support unit as the diagnostic information confirmation 12 and wait for the analysis result.

In the support unit, a large number of experts relating to hardware and software, a digital control device alone and system construction are assembled to analyze the diagnostic information.
Perform step 13 to identify the fault location.

In the identification of the failure location, there are cases where the failure location can be clearly determined, and cases where estimation is made over several types of substrates that are possible. The support unit informs the site of the identification work result, and The on-site maintenance staff and the support team work together to create a board replacement procedure14 for restoration while considering the plant operation status.

This board exchanging procedure preparation 14 is performed when the digital controller 1 is stopped when the board is exchanged.
Estimate the range of influence on the plant such as whether an alarm is issued or an unrelated output signal is generated, and perform isolation work such as jumpers and lifts to keep the plant operating, and The work procedure to be replaced is created correctly. At the site, the work of the board replacement 15 is performed according to the board replacement procedure, and if the failure is eliminated, the recovery is completed.

[0016]

Digital controller 1
When a failure occurs, it is necessary for a large number of people to perform high-density, long-term identification and restoration work for this restoration, especially when a failure occurs at night. However, it was difficult to assemble support units not only in the field but also in an urgent way, so there was an obstacle that it took a lot of time to restore them. Therefore, there has been a demand for the development of a rational support device capable of promptly responding to the identification and restoration of the failure part.

An object of the present invention is to provide a digital control device which has a failure analysis and recovery guidance data and automatically analyzes the failure information data to assist in identifying a failure location and creating a board replacement procedure. The purpose of this is to provide a maintenance support device.

[0018]

To achieve the above object, a maintenance support device for a digital control device according to a first aspect of the present invention decodes failure information from a diagnostic signal of the digital control device and outputs decoded data. Diagnostic signal decoding device,
An abnormality factor analyzer for inputting the decrypted data and extracting the fault factor data from the fault factor database held therein is provided.

Further, an abnormal factor analysis device for outputting abnormal part recognition data from a failure evaluation database held by adding decoding data to the failure factor data, and a similar event in the past from the event storage device to the abnormal part recognition data. An abnormal point identification device that outputs abnormal point identification data in consideration of data and plant operation data from the operation status input device is provided.

Further, an abnormal point exchange condition input device for outputting abnormal point exchange condition data in consideration of the abnormal point identification data from the specified device and the plant status data from the plant status data input device to the abnormal point identification data is provided. ,
The abnormal point exchange guidance data is output by adding the recovery guidance data from the recovery guidance storage device to the abnormal point exchange condition data and outputting the abnormal point exchange guidance data to notify it by a display device or the like.

According to a second aspect of the present invention, there is provided a maintenance support device for a digital control device, wherein the input / output device inputs network information from a plurality of digital control devices and outputs network diagnostic data, and the network diagnostic data is input. A diagnostic signal analyzer for outputting the decoded data and a plant condition data converter for outputting the plant condition data are also provided.

A soundness diagnostic analysis device for outputting soundness diagnosis decoding data, an abnormality factor analysis device for inputting the decoding data and extracting the failure factor data from a failure factor database held therein, and the failure factor data An abnormality factor analysis device is provided which outputs abnormality location recognition data from a failure evaluation database that holds the decrypted data, the plant status data, and the integrity diagnosis decoded data.

Further, an abnormal point identification device that outputs abnormal point identification data by adding past similar event data from an event storage device to the abnormal point recognition data, and plant state data by the abnormal point identification data. An abnormal point exchange condition input device that outputs abnormal point exchange condition data,
The abnormal point exchange guidance data is output by adding the recovery guidance data from the recovery guidance storage device to the abnormal point exchange condition data and outputting the abnormal point exchange guidance data to notify it by a display device or the like.

According to a third aspect of the present invention, there is provided a maintenance support device for a digital control device, wherein a fault factor database held by the fault factor analysis device and a fault evaluation database held by the fault factor analysis device are used as a fault tree analysis to detect a fault. The feature is that the location is identified.

According to a fourth aspect of the present invention, in the maintenance support device for the digital controller, the failure evaluation database for calculating the contribution of the element level failure rate at each location from the failure event is searched for with the failure event data of the decoded data. FM that identifies a failure location by summing the failure rate contributions to failure events at each location
The feature is that an abnormal point analysis analysis is performed by the EA method.

[0026]

According to a first aspect of the present invention, the diagnostic signal decoding device decodes the failure information from the diagnostic signal of the digital control device to obtain decoded data, and the decoded data is stored in the abnormality factor analysis device. The failure factor data is extracted by.

Next, the failure evaluation database held in the abnormality factor analysis device outputs abnormal point recognition data from the failure factor data and the decoded data, and the abnormal point identification device outputs the plant operation data to the abnormal point recognition data. And the similar event data in the past are added to output the abnormal point identification data.

Further, in the abnormal point exchange condition input device, abnormal point exchange condition data is output by adding the abnormal point designation data and the plant status data to the abnormal point identification data, and the abnormal point exchange guidance is added to the abnormal point exchange condition data. The restoration guidance data is added to the equipment to display the abnormal location replacement guidance data on a display device, etc., to assist maintenance personnel.

According to a second aspect of the present invention, the input / output device inputs network information from a plurality of digital control devices as network diagnostic data, and the diagnostic signal decoding device uses the network diagnostic data to detect fault information of the digital control device. To decrypt and output the decrypted data.

The decryption data is extracted from the failure factor database held in the abnormality factor analysis device, and the abnormality factor analysis device uses the failure evaluation database to retain the decryption data and the plant status data in the failure factor data. Abnormal part recognition data is output by adding the sex diagnosis decoding data.

The abnormal point identification device, to which the abnormal point recognition data is input, outputs the abnormal point identification data in consideration of the similar event data in the past, and the abnormal point identification data is output to the abnormal state exchange condition input device in the plant status. Abnormal part replacement condition data is output in consideration of the data.

Further, the abnormal part replacement guidance data is added to the abnormal part replacement condition data by the recovery guidance data, and the abnormal part replacement guidance data is displayed on a display device or the like to assist maintenance personnel.

According to the third aspect of the present invention, the failure factor database held by the abnormality factor analysis device and the failure evaluation database held by the abnormality factor analysis device are used as a fault tree analysis database, and the failure factor data and the failure evaluation data are respectively obtained. And analyze the abnormal part to identify the failure part.

According to the fourth aspect of the present invention, the failure rate for each failure event at each location is searched by searching the failure evaluation database for calculating the contribution of the failure rate at the element level at each location from the failure event with the failure event data of the decoded data. An abnormal place is analyzed by the FMEA method in which a failure place is identified by counting contributions.

[0035]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described with reference to the drawings. It should be noted that the same components as those of the above-described conventional technique are denoted by the same reference numerals and detailed description thereof will be omitted. The first embodiment is a fault tree analysis method for fault search.
nalysis) is adopted as an example. As shown in the block diagram of FIG. 1, the diagnostic signal decoding device 18 of the maintenance support device 17 receives the diagnostic signal 16 which is the diagnostic information of the digital control device 1. In the present invention, it is assumed that the input is online, but the input may be offline such as a floppy disk.

In the diagnostic signal decoding device 18, since the inputted diagnostic signal 16 is a code signal of AZ, 1, 0, etc.,
Decoding this and converting the failure information into technical signals such as the time of occurrence, failure content, position where the failure was detected (unit number, slot number, etc.), transmission path, board type, etc., failure event data and sound event data Output as decrypted data 19 consisting of.

The decrypted data 19 includes a fault tree analysis device 20 (hereinafter abbreviated as FT analysis device), which is an abnormality factor analysis device, a search device 21, and a fault tree analysis device 22 (hereinafter, referred to as an abnormality factor analysis device). Input to the FT analysis device).

The FT analysis device 20 has a fault factor database based on fault trees, and fault factors along the fault tree database 23, which is a fault factor database shown in the fault tree diagram of FIG. The fault tree data 24 which is the data is extracted.

That is, the FT analysis apparatus 20 collates with the fault tree database 23 on the basis of the failure event data, and the fault tree that can be a factor including the related boards is used as the fault tree data 24 in the FT analysis apparatus.
Output to 22.

This FT analysis device 22 has a failure evaluation database 25 shown in the failure evaluation database diagram of FIG. 3, and extracts the failure factor evaluation data of the board from the factor items of this fault tree, and the respective factor items. Decoded data for each
The 19 failure event data and sound event data are collated with the confirmation request contents of the diagnostic data.

If the verification result matches the confirmation request content and is sound, the evaluation is good, and if they do not match, the evaluation is bad and the fault identification points are listed. In addition, the total number as the failure identification portion is displayed as a priority as the order of the board replacement targets.

Therefore, the FT analysis device 22 outputs the board replacement target list including information on the position of the replacement board and the board type and the replacement priority order information to the abnormal part identification device 27 as the abnormal part identification data 26.

When the decrypted data 19 is input to the search device 21, the search device 21 accesses the event storage device 28 to search the past accumulated data according to the failure event data, and the past failure event data and the board are searched. The exchange target data and the like are output from the event storage device 28 as past similar event data 29.

The abnormal point identifying device 27 includes the abnormal point recognition data 26 and the past failure event data 29 from the search device 21,
Operation status input device 30
First, input as plant operation data 31, check the order with the board replacement target again, and use as the abnormal point identification data 32.
Output to the display device 33, the first printer 34, the input device 35, and the abnormal part replacement condition input device 36.

The first display device 33 and the first printer 34 are
The board replacement target list (including unit No., slot No., board type), order, and fault tree analysis results are displayed, and a printout is provided to notify the operator or maintenance staff.

Further, the input device 35 uses the abnormal part identification data 32.
Is output to the event storage device 28 as the storage input data 37. The reason for passing through the input device 35 is to confirm that the abnormal portion identification data 32 is correct with the input device 35 and use it as the storage input data 37. .

The abnormal part replacement condition input device 36 inputs the abnormal part identification data 32 or the manual replacement data as the abnormal part designation data 39 from the designating device 38 for the board replacement data by the operator or maintenance personnel, and at the same time, the operator The operation status of the plant and equipment from the plant status data input device 40 by the maintenance personnel and the process value are input as the plant status data 41.

Specifically, this is the operation at the rated output or 50
% The range of influence at the time of board replacement changes depending on the situation of whether it is operating at% output or which device is operating.
Input to organize the conditions for board replacement.

Further, in the abnormal portion replacement condition input device 36, the replacement target board and the plant status data necessary for each board
41 is combined and output as abnormal point exchange condition data 42 to the abnormal point exchange guidance device 43.

This abnormal part replacement guidance device 43 is connected to a recovery guidance storage device 44 which holds a recovery guidance database for board replacement, and uses the input replacement target board list and plant status data 41. , The recovery guidance database 45 shown in FIG. 4 is searched, and the jumper, the lift list, the presence / absence of an alarm, the variation of the indicator and the recorder are searched depending on the degree of influence at the time of replacement of each replacement target board. The operation of the device and the like are obtained as the restoration guidance data 46.

The board failure recovery guidance database 45 shown in FIG. 4 is subjected to a primary search of data according to the board position and board type of the board to be replaced, and when the corresponding board data is obtained, the degree of influence is evaluated. That is, in general, a single board is associated with 10 points for analog signals and 10 to 30 points for digital signals, and the board of the common control section is further affected.

The operating condition of the plant is 0 relative to the rated condition.
%, 50%, 100%, etc., and the operating status of multiple auxiliary machines such as A, B, etc. are combined with each board signal to check if there is a change in the indicator and recorder, and if there are alarms, and if necessary jumpers and lift points , Select a recovery guidance number that guides the operator appropriately and check the confirmation items.A recovery manual with the recovery guidance number is output from the recovery guidance storage device 44 to the abnormal location replacement guidance device 43 as part of the recovery guidance data 46. To be done.

In the abnormal portion replacement guidance device 43, a jumper for each board, a lifted portion, an indicator and a recorder, an indicator lamp, an alarm, etc. are notified in accordance with the restoration manual, and confirmation items are sorted into work units to detect an abnormality. A second display device 48 and a second printer as the location exchange guidance data 47.
Output to 49.

Also, this abnormal point replacement guidance data
47 is a maintenance support device 17 from the transmission device 50 via the transmission path 51.
It is configured to be output to the process computer 52 that manages the entire plant outside the.

Next, the operation of the above configuration will be described. During operation of the plant, while the digital control device 1 is in operation, the diagnostic signal 16 is input to the diagnostic signal decoding device 18 of the maintenance support device 17, and if a problem occurs in the digital control device 1, the diagnostic signal 16 will be output. Both failure information and sound information are transmitted as code signals.

This code signal is a combination of the alphabets A to Z and the numbers 1 to 9 and indicates the time and the diagnostic result such as failure and soundness of the diagnostic location, and information such as the position where the abnormality is finally detected as the system. include. When the diagnostic signal decoding device 18 includes failure information in the input diagnostic signal 16, it decodes the failure information and outputs failure event data and sound event data as decoded data 19.

The decoded data 19 is a technical term signal such as a failure occurrence time, a failure content, a position where the failure is detected, a transmission path and a board type. The decoded data 19 is FT.
When the data is input to the analysis device 20, the failure factors that can be factors by collating the information such as the content of the failure event data, the board type, and the transmission path with the fault tree database 23 that is the failure factor database held by the FT analysis device 20. The fault tree data 24 of the data is extracted and output to the FT analysis device 22.

The FT analysis device 22 collates the factor items of the fault tree with the failure evaluation database 25 of the board held by the FT analysis device 22, and extracts the failure evaluation database 25 shown in FIG. 3 for each relevant factor item. .

As shown in FIG. 3, the failure evaluation database
Check the diagnostic data confirmation column based on the failure event data and sound event data included in the decryption data 19 entered for each of the 25 factor items, and if the evaluation field is sound, it is judged as good or mismatch. If so, mark it as defective.

Based on the total number of the evaluation results, the results of the failure evaluation database 25, in which priority is displayed as the failure identification location in the replacement object column as the order of the board replacement objects, are arranged,
A board replacement target list indicating the position and board type of the replacement board and priority information are output to the abnormal point identification device 27 as abnormal point identification data 26.

In the abnormal point identification device 27, the plant operation data 31 input separately from the operation status input device 30 is collated again with the past similar event data 29 such as the board exchange information of similar events in the past. While checking, the abnormal point identification data 32 is used as the abnormal point exchange condition input device 36 and the first
Output to the display device 33, the first printer 34, and the input device 35.

As a result, in the first display device 33 and the first printer 34, the operator and maintenance personnel are informed of the position, model, order, etc. of the replacement board.

In the abnormal part replacement condition input device 36, the abnormal part identification data 32 or the abnormal part designation data 39 from the separately designated device 38 and the plant status data input device 40 are input.
Abnormal point replacement guidance device 43 is combined as plant abnormal condition replacement condition data 42 by combining plant status data 41 from
Output to.

The abnormal part replacement guidance device 43 outputs a list signal of the position of the replacement target board and the board type to the recovery guidance storage device 44 which holds the recovery guidance database 45 for the board replacement, and applies it. Extract the restoration guidance data 46, evaluate the plant operation status for each signal name of the board, the operation status of the auxiliary equipment, the presence or absence of a change in the indicator and recorder in the board replacement work, etc., and the presence of an alarm, etc.
Select the recovery guidance number.

Further, the recovery manuals based on the recovery guidance numbers of the respective boards are organized and integrated, and for each work unit, jumpers, lift points, indicators and recorders for operators,
Confirmation items such as indicator light changes and alarms are output to the second display device 48, the second printer 49, and the process computer 52 as abnormal point replacement guidance data 47 to assist operators and maintenance personnel. Provided.

As a result, the maintenance support device 17 automatically analyzes the diagnostic data of the digital control device 1 and, based on the data obtained from the failure information, automatically creates a list of the board position and the board type in which the failure location is identified. indicate.

Further, the restoration guidance data 46 for the substrate exchange is automatically extracted from the list of the substrate position and the substrate type, and the restoration guidance data 46 is collated with the operating condition data of the plant and the auxiliary machinery. Then, the abnormal position support is provided in the recovery manual format such as the board position, model and sequence to be automatically replaced, jumpers, lift work procedures, indicator and recorder and changes in indicator and indicator lamps, alarms, etc. The guidance data 47 is output.

The substrate restoration schedule according to the present invention is shown in the work process diagram of FIG. The horizontal axis represents the time from the occurrence of failure to the recovery, and the vertical axis represents the work element. From failure occurrence to occurrence status confirmation 11 is the same as before, but diagnostic information confirmation 12
The diagnostic information is automatically analyzed, so the time is greatly reduced.

Further, when the condition input 53 such as the plant operating condition which is the plant operating data 31 from the operating condition input device 30 is performed, only the output confirmation 54 of the maintenance support device 17 when exchanging the target substrate is used for the replacement work. 15 can be done.

Therefore, as a first effect, the failure of the digital control device 1 can be dealt with in a short time only at the site. The second effect is that no expert support team is required, only the on-site operators and maintenance personnel can accurately identify the failure location and obtain a recovery manual for board replacement, and eliminate and repair the failure. It can be done quickly.

In the second embodiment, as shown in the block diagram of FIG. 6, in the first embodiment, the digital control device 1 shown in FIG. Maintenance support device corresponding to a system in which the digital control devices 1a to 1n of
56.

In this maintenance support device 56, each digital control device 1a-1
Information data 57 including n diagnostic data is input to the input / output device 58 to convert this optical multiplex signal into an electrical signal, and at the same time, as the network data 59, the diagnostic signal analyzer 18 and the soundness diagnostic analyzer 60, and The data is output to the plant status data converter 40.

In the diagnostic signal analysis device 18, the failure content,
The decoding data 19 indicating the time of occurrence, the board position where the failure is detected, the board type, etc., are analyzed by the FT analysis apparatus 20 and the search apparatus 21 of the abnormality factor analysis apparatus and the FT which is the abnormality factor analysis apparatus.
Output to the analysis device 61.

The FT analyzer 20 has a fault tree database 23, which is a fault factor database for substrates, which can be a fault factor as shown in FIG. 2, and searches for the decoded data 19 including the input fault event to find a fault. The tree data 24 is output to the FT analysis device 61.

Separately from the plant status exchanging device 40, plant operating conditions, auxiliary machinery operating conditions, change conditions at the time of failure occurrence, etc. are treated as plant condition data 41, and further from the soundness diagnostic analysis device 60, each digital control device. The soundness diagnostic analysis data 62, which is information of a sound portion in the diagnosis of 1a to 1n, is output to the FT analysis device 61 together.

In the FT analysis device 61, the relevant factor evaluation data is evaluated from the failure factor evaluation database 25 shown in FIG. 3 which is provided in advance, and this is used as the abnormal part recognition data 26 to identify the substrate considered to be the abnormal cause. The position and the board type are output to the abnormal point identifying device 63.

In the abnormal part identification device 63, the position of the board considered to be the cause of the failure and the board type are compared with the similar event data 29 in the past retrieved from the data in the event storage device 28 by the retrieval device 21. Is output as the abnormal point identification data 32.

This abnormal point identification data 32 is stored in the abnormal point replacement condition input device 64, the first display device 33, and the first printer.
34, and the input device 35, in the first display device 33 and the first printer 34, the unit number of the digital controller 1a-1n in which the failure has occurred, the position of the board, the kind of the board, the replacement Display the order of hits and inform operators and maintenance personnel.

The abnormal point exchange condition input device 64 combines with the plant status data 41 separately input from the plant status exchange device 40 and outputs it as the abnormal point exchange condition data 42 to the abnormal point exchange guidance device 65.

The abnormal point replacement guidance device 65 takes out the corresponding recovery guidance data 46 retrieved from the recovery guidance storage device 44 and extracts the abnormal point replacement condition data 42.
Check the board replacement list, board position, board type, replacement order, jumpers, lifts, indicator and recorder, and indicator lamp changes and alarms, and the operator and maintenance personnel. The confirmation items and the like are output as the abnormal portion replacement guidance data 47 to the second display 48 and the second printer 49 for notification.

According to the above configuration, even if a failure occurs in a plurality of large-scale digital control devices 1a-1n,
Information data including diagnostic data output from each
By inputting 57, one maintenance support device 56 automatically identifies the failure point, and the position and model of the replacement target board and the abnormal point replacement guidance data 47 are sent to the maintenance personnel via the second display device 48 or the like. Since the instruction is given to, it is possible to easily eliminate the failure and restore the normal condition in a short time only by the local maintenance staff without requesting the support of the support unit by the expert in the manufacturing factory.

In the third embodiment, as shown as the embodiments in the above-mentioned first and second embodiments, the fault factor database in the fault search, the fault evaluation database and the identification of the abnormal portion are subjected to the fault tree analysis. The method (Fault Tree Analysis) is adopted.

In the fourth embodiment, the FMEA method (Failure Mode Effect Analysis) for a failure event for each board type is adopted for the failure factor database in the failure search, the failure evaluation database and the identification of the abnormal portion. In the digital controller 1, 1a to 1n, an evaluation analysis is performed for each failure event for each component and element of each board, and the relationship between the reliability data of these components and elements and the failure event is numerically evaluated. Using the weighted relational information as a database, a substrate linked to the failure information data contained in the diagnostic information decoding data 19 is automatically extracted.

This failure information data is related information weighted as shown in the failure influence distribution chart of FIG. Next to No. 9, 10, further No.
In the order of 6, 8, 12, and 16, the abnormal portion is identified by the priority order from the one having the largest quantity of relation information.

Therefore, even if a failure occurs in the digital control device 1, the appropriate abnormal part replacement guidance data 47 relating to the identification of the failed part and the restoration work is first provided on the site.
The display device 33 and the first printer 34, and the second display device 48 and the second printer 49 are automatically provided to the operator and maintenance personnel. Even if a breakdown occurs at night, this support data enables quick recovery without waiting for support from the support unit.

[0086]

As described above, according to the present invention, the first effect is to automatically identify an abnormal portion from a large number of boards when a digital controller fails, extract a board to be replaced, and perform restoration work. Since the abnormal point replacement guidance data is automatically provided at the time of restoration, the recovery time is greatly shortened and the plant operation rate is improved.

As a second effect, the replacement target board and the restoration support guidance are automatically provided on the spot without the need of an expert of the support unit, so that the precision of the restoration work is improved.

The third effect is that it is generally difficult to find out the cause of failure due to the increase in size and complexity of the digital controller, but the black box part is visualized to find out the cause of failure and prepare a procedure for restoration work. Has the effect that it can be simplified.

[Brief description of drawings]

FIG. 1 is a block configuration diagram of a maintenance support device according to a first embodiment of the present invention.

FIG. 2 is a fault tree diagram of a failure factor database according to an embodiment of the present invention.

FIG. 3 is a diagram of a failure evaluation database according to an embodiment of the present invention.

FIG. 4 is a recovery guidance database diagram of the first embodiment according to the present invention.

FIG. 5 is a process diagram of maintenance support work of the first embodiment according to the present invention.

FIG. 6 is a block configuration diagram of a maintenance support device according to a second embodiment of the present invention.

FIG. 7 is a failure influence distribution diagram of the fourth embodiment according to the present invention.

FIG. 8 is a perspective view of a conventional digital control device.

FIG. 9 is a conventional maintenance support work process diagram.

[Explanation of symbols]

1, 1a to 1n ... Digital control device, 2 ... Power supply device,
3 ... CPU board, 4 ... Memory board, 5 ... Diagnostic information board,
6 ... Battery board, 7 ... Transmission control board, 8 ... I / O board, 9 ... Solid line (field work), 10 ... Dashed line (support unit), 11
… Confirmation of occurrence status, 12… Confirmation of diagnostic information, 13… Analysis work, 14
… Circuit board replacement procedure creation, 15… Board replacement work, 16… Diagnostic signal, 17, 56… Maintenance support device, 18… Diagnostic signal decoding device, 19
… Decoded data, 20… FT analysis device, 21… Search device, 22,
61 ... FT analysis device, 23 ... Fault tree database, 24 ... Fault tree data, 25 ... Failure evaluation database, 26 ... Abnormal point recognition data, 27, 63 ... Abnormal point identification device, 28 ... Event storage device, 29 ... Past Similar event data, 30 ... Operation status input device, 31 ... Plant operation data,
32 ... Abnormal part identification data, 33 ... First display device, 34 ... First printer, 35 ... Input device, 36, 64 ... Abnormal part replacement condition input device, 37 ... Stored input data, 38 ... Designation device, 39 …
Abnormal point designation data, 40 ... Plant status data input device, 41 ... Plant status data, 42 ... Abnormal part replacement condition data, 43, 65 ... Abnormal part replacement guidance device, 44 ... Recovery guidance storage device, 45 ... Recovery guidance database, 46 ... Restoration guidance data, 47 ... Abnormal portion replacement guidance data, 48 ... Second display device, 49 ... Second printer, 50 ... Transmission device, 51 ... Transmission path, 52 ... Process computer, 53 ... Input condition, 54 ... output confirmation, 55 ... network, 57 ... diagnostic information, 58 ... input / output device, 59 ... network data, 60 ... soundness diagnostic analysis device, 62 ... soundness diagnostic analysis data.

Claims (4)

[Claims] 1. A diagnostic signal decoding device for decoding failure information from a diagnostic signal of a digital control device and outputting the decoded data, and an abnormal factor for extracting the failure factor data from a failure factor database held by inputting the decoded data. An analysis device, an abnormality factor analysis device that outputs abnormal point recognition data from a failure evaluation database that holds the decoding data in addition to the failure factor data, and similar past event data from an event storage device to the abnormal point recognition data An abnormal point identification device that outputs abnormal point identification data in consideration of the plant operation data from the operation status input device, and a plant from the abnormal point specification data and the plant status data input device from the specified apparatus to the abnormal point identification data An abnormal point replacement condition input device for outputting abnormal point replacement condition data in consideration of situation data; A digital control device characterized by comprising an abnormal point exchange guidance device which outputs abnormal point exchange guidance data by adding recovery guidance data from a recovery guidance storage device to abnormal point exchange condition data and notifies it on a display device or the like. Maintenance support device. 2. An input / output device for inputting network information from a plurality of digital control devices and outputting network diagnostic data, a diagnostic signal analysis device for inputting the network diagnostic data and outputting decoded data, and the same plant. A plant status data conversion device that outputs status data, a soundness diagnosis and analysis device that outputs soundness diagnosis decoding data, and an abnormality factor analysis device that inputs the decoding data and extracts the failure factor data from a failure factor database that is held And an abnormality factor analysis device that outputs abnormal point recognition data from a failure evaluation database that is stored by adding decoding data, plant status data, and soundness diagnosis decoding data to the failure factor data, and event storage in the abnormal point recognition data. The abnormal part identification data is added by taking into account the past similar event data from the equipment. An abnormal point identification device that outputs
Abnormal part replacement condition input device that outputs abnormal part replacement condition data by adding plant status data to the abnormal part identification data, and abnormality by adding recovery guidance data from a recovery guidance storage device to the abnormal part replacement condition data A maintenance support device for a digital control device, comprising: an abnormal location exchange guidance device which outputs location exchange guidance data and notifies it by a display device or the like. 3. The fault factor database held by the abnormality factor analysis device and the fault evaluation database held by the abnormality factor analysis device are databases according to a fault tree analysis method.
A maintenance support device for the digital control device described. 4. A failure location is obtained by searching a failure evaluation database for calculating the contribution of the failure rate at the element level of each location from the failure event with the failure event data of the decoding data and totaling the failure rate contribution to the failure event at each location. The abnormal area analysis and analysis is performed by the FMEA method for identifying a fault.
Alternatively, the maintenance support device for the digital control device according to claim 2.