JPH0895634A - Method for monitoring plant and device therefor - Google Patents

Abstract

PURPOSE: To provide a plant monitoring method and device which can automatically search for the factor of abnormality of a plant operation without using any program tool. CONSTITUTION: A program equal to a program 121 that is carried out by a controller 1 is stored also in storage 24 of a monitoring device 2 (241). When an abnormality signal is detected in a normal monitor mode, the program stored in the storage 24 is retrieved with an abnormality signal used as a key. Then a signal serving as an arithmetic input of the abnormality signal is extracted as a candidate signal of the abnormality factor together with its composition attribute and then managed in a factor candidate table 243. Furthermore, the present signal states are read out of a data part 122 of the controller 1 for each candidate signal and compared with the attribute. Thus a signal unmatched with the composition attribute is decided as factor signal of non-composition among those candidate signals. If a factor signal is the internal signal that is produced in the controller 1, the factor signal is recursively retrieved.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plant operation state monitoring device, and more particularly to a method for searching for a cause when an abnormality occurs in plant operation.

[0002]

2. Description of the Related Art A plant monitoring device displays on a screen such as a CRT.
For example, the operation status of the plant is monitored by displaying the system and process signals of the entire plant or specific equipment. These screens are completed by designing the signals necessary for operation and their display forms at the time of planning the monitoring device, and making each screen based on the designed signals.

When an abnormality occurs in the plant, the operator searches for the true cause of the abnormality using the abnormality signal displayed on the monitor screen as a clue. In this case, if the cause of the abnormality is related to the internal signal generated by the execution program of the controller (hereinafter referred to as the controller program),
Since it is necessary to open many pages using a programming tool to investigate the cause, it takes time and labor, and quick response becomes difficult.

As a countermeasure against this, Japanese Patent Laid-Open No. 4-137010
As described in Japanese Patent Laid-Open Publication No. 2004-242242, there is known a method of examining a portion where an abnormal signal is generated from a controller program, finding an external fetch signal from the portion, and extracting it as a candidate factor of the abnormal cause.

[0005]

In the prior art cited above, the external signal related to the original abnormal signal is picked up from the program, but the search for the cause when there are a plurality of candidate factors must be conducted by the operator. It is entrusted.

Further, the candidate factor is limited to the external setting signal. However, since the original abnormal signal is output through the processing of the controller, its generation often includes an internal signal by the operation of the program. Therefore, if this internal signal is not used as a candidate factor, the signal can still be found even if the external setting signal is the cause as a result of recursively finding the candidate factors of this internal signal. Is not guaranteed, and the accuracy of the cause search is low.

It is an object of the present invention to provide a plant monitoring method and apparatus which can automatically search for a cause of abnormal operation of a plant and can contribute to improving the productivity of the plant by taking prompt measures against accidents.

Another object of the present invention is to provide a highly reliable plant monitoring method and apparatus by searching the cause of a true abnormality including an internal signal.

Still another object of the present invention is to provide a plant monitoring method and apparatus in which an operator can easily confirm the cause by a tree display of a search process.

[0010]

SUMMARY OF THE INVENTION It is an object of the present invention to receive a predetermined signal from a controller for controlling a plant and monitor the operating state of the plant. When the abnormal signal of the operating state is detected, the controller The same program as the program is searched to extract a candidate signal that may be a cause of the abnormal signal, and the current data (on / off) is read from the controller for this candidate signal and preset for the candidate signal. This is achieved by comparing the attribute data (on / off) of the signal establishment and determining the candidate signal as the original abnormal signal cause signal when the current data and the attribute data do not match.

Another object of the present invention is to search for the same program as the controller program when an abnormal signal of an operating state is detected, to extract a candidate signal which may be a factor of the abnormal signal, and to extract each candidate signal. The current data (on / off) is read from the controller and compared with the preset attribute data (on / off) for the candidate signal, and if the current data and the attribute data do not match, the candidate is selected. This is achieved by determining the signal as a factor signal of the original abnormal signal and recursively extracting the factor signal when the factor signal is an internal signal of the controller.

Still another object of the present invention is achieved by sequentially displaying the original abnormal signal and the recursively extracted factor signal in a tree shape.

[0013]

According to the present invention, the same program as the program executed by the controller is also provided in the monitoring device, and the same program is searched using the abnormal signal detected by the normal monitoring mode when the plant is abnormal as a key. A signal that is an operation input of the abnormal signal is extracted as a candidate signal of the abnormal factor together with its established attribute, and the current state is read from the controller for each candidate signal and compared with the attribute.

Therefore, when the abnormal signal is not satisfied, it is possible to automatically determine, as a factor signal of the failure, a signal that is currently out of agreement with the satisfied attribute in the candidate signals, and the above causes can be promptly compared with the conventional one. Can diagnose and take measures against accidents.

Further, not only the external signal but also the internal signal created inside the controller becomes a candidate signal. In the case of the internal signal, the factor signal thereof is recursively searched. The factor signal finally extracted is often an external signal, but may be an internal signal. As described above, since the cause search including the internal signal is enabled, the diagnosis of the cause of the abnormality of the plant monitoring device becomes accurate and the reliability can be improved.

Furthermore, since the factors of the search process are displayed in a tree, the process leading to the final factor can be easily understood by the operator and the validity of the diagnosis can be easily confirmed, which is convenient.

[0017]

An embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 shows the configuration of an embodiment of the plant monitoring control system according to the present invention. Controller 1 is C
PU11, main memory 12, PIO13 and communication means 14
It consists of The main memory 12 includes a storage unit 121 for a controller program executed by the CPU 11 and a data storage unit 1 for storing process data, calculation data, and the like.
22. The controller 1 takes in process data and outputs a plant control command via the PIO 13. Further, data is transmitted / received to / from the plant monitoring device 2 via the communication means 14 and the network 5.

The plant monitoring device 2 switches the process of the plant monitoring device 2 to the monitoring mode / fault analysis mode in response to an instruction from the screen display processing means 21 for processing the display output to the display 3 and the input device 4. Means 22, failure search processing means 23 for searching for cause of failure, storage means 24 having program storage section 241, related data storage section 242, factor candidate table storage section 243, network 5
It is composed of a communication means 25 that transmits and receives to and from the controller 1 via.

The program storage unit 241 stores the same program as the controller program, which is read out as a search symmetry at the time of failure search. Further, the screen display processing means 21 has a plant monitoring screen display function 211 that is executed in the monitoring mode and a failure search screen display function 212 that is executed in the failure search mode.

The plant monitoring device 2 normally executes in the monitoring mode, and the plant monitoring screen display function 211 displays the current data of the parameters preset for each screen on the operating state display screen of the entire plant or a predetermined part. It is read from the controller 1 and displayed to support the operator's plant monitoring and operation. Note that the configuration of the normal monitoring mode in this embodiment is well known, and details thereof will be omitted.

Next, the structure of the failure search mode, which is a feature of this embodiment, will be described. FIG. 2 shows a processing flow of the failure search processing means.

When the operator finds an abnormal signal from the plant monitoring screen or the alarm, the operator switches to the failure search mode,
Start searching for the cause of the failure. First, the signal name of the abnormal signal (in the actual program, an address for storing the signal is used instead of the signal name) is given from the input device 4 (s101). Next, the controller program is read, the program contents are searched in the forward direction from the beginning, and the output location (signal writing location) of the signal name (or address) is detected (s102). Further, the program is traced in the reverse direction from this output location to search for the logic start position (s103). This is done by looking for the description pattern of the instruction. In case of external input, start position =
It will be the output location.

Next, with respect to each signal described in the range from the logic start position to the output position, the address and attribute (whether the signal is established by ON or OFF) is read, and the name of each signal and the address and attribute are compared. The data is stored in the factor candidate table 253 (s104). The attribute of a signal can be detected by the description format of the instruction for the signal. For example, in a store instruction, "QST" is ON, QCST.
Is satisfied with "OFF". The correspondence between the signal name and the address is defined in advance when the controller program or the image display processing procedure is created, and is set in the related data storage unit 252 so that it can be referred to. Of course, it may be a definition on a program.

Next, for each signal of the factor candidate collected in the factor candidate table 253, the current data is read from the controller 1 (s105), and the mismatched signal is not established as compared with the attribute set in the table. It is extracted and displayed as a factor signal of (s106). Note that the number of factor signals is not limited to one and may be plural.

Next, it is determined whether or not this factor signal is due to external setting (s107). The input from the outside can be identified from the above-mentioned start position = output position or the address value of the signal (address value of the sensor or external device), and in this case, it can be immediately determined to be the cause of the abnormality.

On the other hand, since the factor signal not depending on the external setting is the internal signal generated in the controller 1, the above steps s101 to s106 are recursively repeated. As a result, the signal is finally narrowed down to one or a plurality of factor signals, and in this case as well, it is often an external setting signal.

However, the final factor signal may be an internal signal generated by the logic in the controller. For example, if A> B, turn ON C, otherwise, OF
There is a software SW called F. Although the condition A is corrected to perform the mode switching process or the like, if the condition setting of the software SW is omitted, the switching process cannot be executed because the condition C is not satisfied. In the present embodiment, it is possible to search for such an internal signal.

It is possible to automatically re-designate the signal name (or address) of the internal signal among the factor signals extracted in s106 and repeat the above process.
Further, in order to confirm the search process of the cause of abnormality which is performed recursively in this way, s1
The factor signal names extracted in 06 are sequentially displayed in a tree shape.

Next, an example in which the present invention is applied to a rolling plant will be described with reference to FIGS. FIG. 3 shows an operation preparation procedure of the rolling mill in diagrams (a) to (d), and FIG.
3 shows a controller program corresponding to FIG.

Now, the "rolling preparation completed" signal is not established (ON
However, it is assumed that there is a trouble that the rolling mill does not operate. As shown in FIG. 3D, the failure of the "rolling preparation completed" signal (M100) indicates that "common interlock (M100)" has occurred.
200) ”is OFF, or“ Automatic condition entered (M2
02) ”and“ manually entered (M212) ”are both OF
It occurs in the case of F. Also, "common interlock",
The “automatic condition entered” and the “manual condition entered” are established according to FIGS. 3A, 3B, and 3C, respectively.

When the operator finds that the "rolling preparation completed" signal is not established on the normal monitoring screen, the operator specifies the failure search mode from the keyboard 4 and specifies "rolling preparation completed" as the abnormal signal (name). In response to this, the failure search processing means 2
4 reads the controller program of FIG. 4 and sequentially searches from the beginning of the program by using the address = M100 corresponding to the signal name “rolling preparation completed” as a key and issuing the command “QST
Find the output position 301 of "M100". Further, the logic start instruction of this instruction is searched for in the head direction of the program to find the start position 302. From this, it can be seen that the signal at the address M100 is the result of the OR of M202 and M212 and the AND of M200. Each of these signals is stored in the factor candidate table 253 together with the attribute as a candidate signal of the failure factor.
In the case of this example, all the attributes of each signal are ON from the description format of the instruction (since C is not included).

FIG. 5 shows the format of the factor candidate table 253. The failure search processing means 24 refers to the corresponding data of the address and the signal name stored in the related data storage unit 252, and manages the signal name, address, attribute and current state of each candidate signal in a table.

Next, addresses M202, M212 and M
For each signal of 200, the controller 1 is inquired, and the current data is read from the same address of the data storage unit 122. From the comparison between the “attribute” and the “current state”, in the example of FIG. 5, the failure of M202 and M212 is detected, and “automatic condition entry” and “manual condition entry” are displayed on the display 3 as factor signals.

FIG. 6 shows a screen display example of these factor signals. The failure search screen display function 212 sequentially displays the factor signals found by the failure search in a tree shape starting from the original abnormal signal (“rolling preparation completed” in the above example). The display is performed by the signal name corresponding to the address. At this stage of this example, “rolling preparation completed” 401 to “automatic condition completion” 402 and “manual condition completion” 403 in FIG.

Next, when "automatic condition completion" of M202 is designated as an abnormal signal and the controller program is searched again, it is found that this signal is an AND of "automatic mode entered" and "rolling condition reception completed". It is managed in the factor candidate table 253 and the current state of the signal is read from the controller 1. As a result, it is detected that “rolling condition reception complete” is not established, and “rolling condition reception complete” is displayed in the tree of FIG. 6A.
The signal name 404 is additionally displayed.

Further, when "manual condition complete" of M212 is designated as the abnormal signal, the above processing is repeated to "enter manual mode", "roll down pressure setting complete", "plate thickness setting complete" and "line speed setting complete". Among the AND conditions of ", the signal names 405 to 407 are tree-displayed by detecting the failure of the former three.

As described above, when all of the factor signals 404 to 407 extracted for the abnormality of the "rolling preparation completed" signal are externally set, the failure search processing ends.

By the way, in the above example, the non-fulfillment factor occurs in both the "automatic mode" in which the condition is set from the host computer and the "manual mode" in which the operator sets the condition. In an actual plant, only one of automatic / manual mode is set, so it is possible to further narrow down the relevant factors by incorporating this operation mode. In the above case,
When “automatic mode” is selected, all factors related to manual operation are deleted as shown in FIG. 6B, and “rolling condition reception complete” 4
It is limited to the failure of 04. As a result, it can be determined that the true cause of the rolling mill not being able to start is an abnormality of the host computer side or the communication means, and countermeasures can be taken.

[0040]

According to the present invention, when a plant operation is abnormal, a candidate for a failure factor that can be generated by a program is searched for, and the failure factor can be automatically determined by matching with the processing data of the controller. Has the effect of promptly diagnosing.

According to the present invention, since it is possible to determine the failure factor that goes through the internal processing of the controller, it is possible to accurately search the cause of the abnormality and improve the reliability.

According to the present invention, the factors on the way to the cause of the abnormality can be displayed in a tree structure, so that the validity of the cause of the abnormality can be easily confirmed and the reliability can be improved.

[Brief description of drawings]

FIG. 1 is a configuration diagram of an embodiment of a plant monitoring apparatus according to the present invention.

FIG. 2 is a flowchart illustrating an example of an accident cause search process of the plant monitoring method of the present invention.

FIG. 3 is a diagram showing an operation preparation procedure of a rolling mill which is an application example of the present invention.

FIG. 4 is a controller program showing a part of the procedure of FIG.

FIG. 5 is a format diagram of a factor candidate table.

FIG. 6 is a tree display screen showing a factor search process.

[Explanation of symbols]

1 ... Controller, 2 ... Plant monitoring device, 3 ... Display device (CRT), 4 ... Input device (keyboard), 5 ... Network, 11 ... CPU, 12 ... Main memory, 121 ... Controller program storage part, 122 ... Data storage Department,
13 ... Communication means, 14 ... PIO, 21 ... Image display processing means, 211 ... Plant monitoring screen processing function, 212 ... Failure search screen processing function, 22 ... Mode switching means, 23 ... Failure search processing means, 24 ... Storage device, 241 ... Controller program storage unit, 242 ... Related data storage unit, 243
... factor candidate table, 25 ... communication means.

Claims (10)

[Claims] 1. A method of receiving a predetermined signal from a controller for controlling a plant to monitor a plant operating state, and when an abnormal signal of the operating state is detected, the same program as the controller program is searched and the abnormality is detected. A candidate signal that can be a factor of a signal is extracted, the current data (on / off) is read from the controller for this candidate signal, and attribute data (on / off) that is predetermined for the candidate signal is used as attribute data (on / off). A plant monitoring method, wherein the candidate signal is compared with the original abnormal signal when the current data and the attribute data do not match. 2. Received predetermined process data and control data from a controller controlling the plant,
In the method of monitoring the plant operating status, when an abnormal signal of the operating status is detected, the same program as the controller program is searched to extract candidate signals that may be the cause of the abnormal signal, and each candidate signal is output from the controller. The current data (on / off) is read out and compared with predetermined attribute data (on / off) for the candidate signal, and when the current data and the attribute data do not match, the candidate signal is selected. A plant monitoring method characterized in that it is determined as a factor signal of an original abnormal signal, and when the factor signal is an internal signal of a controller, the factor signal is recursively extracted. 3. The factor signal according to claim 2, wherein when the processing route of the recursive extraction of the factor signal is branched, the factor signal finally extracted for each processing route is determined to be a factor for establishing the original abnormal signal. A plant monitoring method comprising: 4. The plant monitoring method according to claim 2, wherein the factor signal finally extracted is an external setting signal. 5. The plant monitoring method according to claim 2, 3 or 4, wherein the finally extracted factor signal is an internal signal generated inside a controller. 6. The method according to claim 3, 4 or 5, wherein there are a plurality of processing routes for the finally extracted factor signals, and the routes are in conflicting plant operating conditions,
A plant monitoring method comprising selecting a cause signal of a processing route corresponding to a set operating condition. 7. The plant monitoring method according to claim 2, 3, 4, 5, or 6, wherein the original abnormal signal and the recursively extracted factor signal are displayed in a tree shape. 8. A method for receiving and displaying predetermined process data and control data from a controller controlling a plant and monitoring the operating state of the plant, in which the same program as the controller program and when the program is created are prepared in advance. Stores the corresponding data of the defined signal name and address, and searches the same program based on the detected abnormal signal of the plant operating state to find the writing position of the abnormal signal and the logic start position of the abnormal signal. The candidate signal that is located between the two positions and may be a factor of the abnormal signal and the attribute of the signal establishment are searched for, and the address and attribute of each searched candidate signal are managed, and the data is stored in the data storage means of the controller. Read the current data (on / off) and compare with the attribute data If the candidate signal is a factor signal of the original abnormal signal when the attribute data and the attribute data do not match, and if the factor signal is an internal signal of the controller, the factor signal is recursively extracted, A plant monitoring method characterized by displaying factor signals of an extraction process in a tree form. 9. A plant monitoring apparatus comprising a controller for controlling a plant according to a controller program and a display device for displaying predetermined process data and control data received from the controller, the same program as the controller program, and the program. A storage device that stores the correspondence data of the address and the signal name defined at the time of creation of the plant, and based on the fault signal of the plant operating state, search the same program read from the storage device and calculate the fault signal. A signal within a (logic) range and attribute data for establishing the signal are extracted, the address and attribute of each signal thus extracted are managed, and the current data (on / off) is read from the controller. Compare the data with the current data, and if there is a mismatch, Signal is determined to be the factor signal of the original abnormal signal, and when the factor signal is an internal signal of the controller, a fault search processing means for recursively extracting the factor signal, the abnormal signal and the recursive signal A plant monitoring apparatus comprising image display processing means for displaying a tree display of extracted factor signals. 10. The method according to claim 9, further comprising a plant monitoring mode for displaying the predetermined process data and control data and a mode switching means for switching a mode for executing the failure search processing means. Plant monitoring equipment.