JPH09152911A - Fault analyzer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To retrieve a data file satisfying a trigger condition out of a previously collected data file group when a fault occurs in a plant for iron and steel, chemical or the like and to display the retrieved data file on a screen together with preceding and succeeding data. SOLUTION: A data collecting part 3 collects data to be collected set up by a collecting data setting part 2 from a plant controller 1 and prepares a collected data file group 4. On the other hand, a trigger condition coincidence detecting part 6 detects a corresponding data file based upon a trigger condition set up in a trigger condition setting part 5 and the number of times of reading out preceding and succeeding data files, a display data generating part 7 combines the detected data file with a preceding and succeeding data file and generates a retrieved result file 8 and a data display edition part 9 displays the file 8 on a CRT display device 10.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a failure analysis device for analyzing the cause of a failure that has occurred in a steel, chemical or other plant.

[0002]

2. Description of the Related Art FIG. 9 is a diagram showing an outline of an electronic exchange system incorporating a conventional system bus monitor device disclosed in, for example, Japanese Patent Application Laid-Open No. 2-121453. In the figure, reference numeral 21 denotes an electronic exchange, and this electronic exchange 21 has a plurality of processors 22 for executing exchange operations such as call processing.
a, 22b, to 22n, a common memory 23 used for data transfer between these processors, and a common bus (system bus) for connecting the processor and the common memory to each other to transmit and receive data. It is composed of 24. Further, each of the processors 22a and 22 described above
b to 22n are responsible for various processing functions of the electronic exchange 21 in a distributed manner, and execute a series of exchange operations while appropriately transmitting and receiving processing data to and from other processors via the common bus 24. .

The system bus monitor device of the electronic exchange 21 is connected to the common bus 24 and an interface card 25 for outputting data on the bus in parallel to the outside.
And a data storage unit 2 for storing all data collected from the common bus 24 via the interface card 25.
6, a display data selection unit 27 that selectively extracts only data that satisfies a predetermined monitoring target condition from the data stored in the data storage unit 26, and the data selected by the display data selection unit 27 is displayed. And a console 28 that operates.

Next, the operation of the above conventional device will be described. In the system bus monitor device, the electronic exchange 21
The data flowing on the common bus 24 to which the respective processors 22a to 22n are connected is transmitted to the data storage unit 26 via the interface card 25 in a form of interception and collected. Failure analysts can
(1) Information identifying the data source processor, (2) Information identifying the access address (or address range) to the common memory 23, (3) Information identifying the access form (read or write), etc. By setting the monitor target condition of, the display data selection unit 27 searches the data in the data storage unit 26 for the data that matches the monitor target condition, and if the data that matches the monitor target condition is found, the data is searched. It is extracted from the collected data and displayed as a list on the console 28.

[0005]

Since the conventional system bus monitor device is configured as described above, all or selected data flowing on the common bus is collected and the monitored condition is set after data collection. As a result, only the data that matches the monitored condition is selected from the collected data and displayed on the screen. In this system bus monitor device, all data flowing on the common bus is stored, and the conditions to be monitored are set after data collection.Therefore, it is not possible to confirm the occurrence of a phenomenon even if it rarely occurs. it can. However, when a failure occurs in a plant such as steel and chemicals, operation command signals to various drive devices arranged in the plant up to the failure state are output rather than information that the failure has occurred. The transition of the signal change from the state detector such as a sensor is important, and there is a problem that substantial failure analysis cannot be performed even if only the data under the monitored condition is searched and displayed from the collected data. . In case of some failure,
What kind of operation command was output to each drive, what kind of behavior each drive was operating based on that operation command, and what kind of state as a plant when a failure occurred This is because it is necessary to know if it has fallen. By analyzing these, it becomes possible to correct the output circuit of the inconvenient operation command that caused the failure, and to limit the detectors that have failed, and in the future if a similar failure occurs in the plant. It is possible to take measures to minimize the damage.

The present invention has been made to solve the above problems. When a trigger condition, which is a data search condition set by a failure analyst, is set, the trigger condition is matched from the collected data files. That has the trigger points specified by the failure analyst, read the data files for the number of times the collected data before and after the trigger point specified by the failure analyst, and read the data files containing the trigger points and the data files before and after that. An object of the present invention is to provide a failure analysis device that combines and displays on the screen.

[0007]

A failure analysis apparatus according to the invention of claim 1 constantly collects all or selected data in each controller for controlling a plant in a constant cycle and selectively collects each collection opportunity. Data file collecting means for storing the above data as one data file, and means for setting the condition of each signal that is assumed to appear when a failure occurs as a trigger condition either alone or in combination. And the trigger condition match search means for searching a data file that matches the set trigger condition from the collected data file group, and the trigger condition match data file detected by the trigger condition match search means and the preceding and following read parts. A display data generating means for combining the data files to be combined and a means for displaying the display data on the screen are provided. It is.

According to the failure analysis device of the invention of claim 1,
By setting a trigger condition that is a condition for a failure analyst to search for desired data, not only the data satisfying the condition is read, but also the data before and after the data are read at the same time to grasp the progress of the failure. Since it is possible to analyze the failure, not only can failure analysis be facilitated, but the state of the plant after the failure can be confirmed, so that countermeasures against the failure can be easily taken.

In the trigger condition setting mechanism according to the second aspect of the present invention, the fault condition in the plant is defined by an ON / OFF value of bit type data or a logical combination thereof,
The desired data is extracted from the data file group.

Further, the trigger condition setting mechanism according to the third aspect of the present invention defines the fault condition in the plant by the value of the word type data or its logical combination, and extracts the desired data from the data file group. It was done like this.

Further, the trigger condition setting mechanism in the invention of claim 4 defines the fault state in the plant by the state change amount of the word type data or its logical combination, and selects the desired data from the data file group. It is designed to be extracted.

Further, the trigger condition setting mechanism according to the invention of claim 5 defines a failure state in the plant by a combination of ON / OFF values of bit type data and values of word type data, and sets the data file group The desired data is extracted from the inside.

Further, the trigger condition setting mechanism according to the invention of claim 6 defines a failure state in the plant by a combination of ON / OFF values of bit type data and state change amount of word type data, and sets the data file. The desired data is extracted from the group.

Further, in the trigger condition setting mechanism according to the invention of claim 7, the fault condition in the plant is defined by the combination of the word type data and the state change amount of the word type data, and the desired condition is selected from the data file group. The data to be extracted is extracted.

The trigger condition setting mechanism according to the invention of claim 8 is a combination of an ON / OFF value of bit type data, a value of word type data, and an amount of change in state of word type data for a failure state in the plant. , And desired data is extracted from the data file group.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 FIG. Hereinafter, a first embodiment of the present invention will be described with reference to the drawings. In FIG. 1, 1 is a controller that controls a plant and inputs various data. 2 is a collection data setting unit for selecting a data item to be collected and setting a fixed cycle time of collection time. 3 is a collection data setting. A data collection unit that collects various data from the controller 1 based on the setting contents of the unit 2, 4 is a collected data file group that stores and saves various collected data in time series, and 5 is for analyzing the stored data. A trigger condition setting unit for setting a trigger condition, 6 is a collected data file trigger condition matching search unit for searching whether or not the above trigger condition matches the collected data of the collected data file group 4 under the set trigger condition, 7 Is for processing the collected data before and after the collected data found by the matching search and the collected data corresponding to the result of the matched search into data for CRT display. Display data generation unit, 8 Result file stores the collected data displayed machining, the CRT collected data of the search result files 8 9
The data display editing unit 10 for displaying, editing, and outputting is a CRT display for displaying and outputting the collected data as a result of matching search under the trigger condition.

FIG. 2 shows the setting contents of the trigger condition setting unit 5 of FIG. 1 in which a logical combination of ON / OFF of bit type data is set as a trigger condition, and when the trigger conditions are matched, the matched trigger points are collected. 9 is a trigger condition setting table for setting the number of read data.

Next, the operation of the first embodiment will be described. Various data used in the plant are input into the controller 1. In the collection data setting unit 2, selection of various data collection items in the controller 1 and a data collection cycle are set. On the other hand, the data collection unit 3 collects the collection data items selected from the setting contents of the collection data setting unit 2 at a set constant collection cycle, and stores them in the collection data file group 4. The collected data file group 4 is stored in the next file when the collected data capacity of one file becomes full due to the passage of time, and constitutes a file group of the amount corresponding to the collection time. Data is collected and stored sequentially.

The analysis method of the data collected as described above is defined by the trigger condition setting section 5 for failure analysis. The trigger condition setting unit 5 sets trigger conditions in a table format as shown in FIG. The setting contents are such that when a certain collected data is viewed as bit type data, it is turned on or off, and it is used as a trigger condition, and the bit type data of one collected data and the bit type data of another collected data are ANDed. As in the case where the result is ON, the logical combination of bit type data is set as the trigger condition.
Furthermore, by setting the number of read outs of the collected data before and after the trigger point (time) at which the trigger condition is detected, the history before and after the data to be analyzed can be grasped.

The collected data file trigger condition coincidence detection unit 6 searches the files of the collected data file group 4 for collected data that matches the trigger condition based on the setting contents of the trigger condition setting unit 5. Specifically, the collected data stored in the collected data file group 4 is examined in chronological order. As shown in the trigger condition setting table of FIG. 2, does it match the logical combination condition of bit type data? Determine whether If they match, the collected time is set as a trigger point. If they do not match, the collected data for the next collection time is determined. Search until the action matches.

When the collected data that matches the trigger condition is detected, the collected time is used as the trigger point, and the display data generation unit 7 displays the collected data in an amount corresponding to the number of read data before and after set in the trigger condition setting table. It is stored in the search result file 8 after being processed into data for use. The search result file 8 stores the collected data before and after the trigger point for all items of the collected data stored in the collected data file group. Thus, the collected data before and after including the trigger point to be analyzed is extracted.

After that, the result is displayed and output on the CRT display 10 in order to see the result of matching search under the trigger condition.
Alternatively, the data display editing unit 9 performs display editing for CRT display, such as selecting only the collected data item to be viewed and scrolling it. As a result, the collected data can be analyzed including before and after the timing of the trigger condition, so the state of each data up to the trigger condition or the operating state after the trigger condition can be confirmed, and the control status and abnormal status of the plant can be analyzed. Is possible.

Embodiment 2 FIG. In the first embodiment, as the setting content of the trigger condition setting unit 5, the collected data is set to be a bit condition and the trigger condition is set to search for a match as shown in FIG. It is also possible to set the trigger condition as. In FIG. 3, data is expressed in a table format by word type data,
A trigger condition is set by using the result of the size comparison with a certain value or the result of the size comparison of the word type data between the collected data as a logical condition with the result of the size comparison of another word type data. This makes it possible to analyze analog data.

Embodiment 3. In the second embodiment, the trigger condition setting unit 5 sets the trigger condition for the collected data as shown in FIG. 3 by using the word type data and searches for a match. However, the amount of state change of the collected data is used as the trigger condition. It is also possible to set as. In FIG. 4, data is represented by word-type data in a tabular form, and the result of comparing the state change amount of certain collected data with a certain value and the logical condition between these results are set as trigger conditions. still,
It is also possible to set the time difference when setting the amount of change. This makes it possible to analyze an analog data change amount.

Embodiment 4 In the first embodiment, the trigger condition setting unit 5 sets the trigger condition for the collected data as shown in FIG. 2 using bit type data and searches for a match. It is also possible to set the trigger condition as a combination of type data. In FIG. 5, data is set in a tabular form as a logical condition such as AND or OR of a bit-type data trigger condition and a word-type data trigger condition.

Embodiment 5 In the first embodiment, the trigger condition setting unit 5 sets the trigger condition for the collected data as shown in FIG. 2 using bit type data and searches for a match. It is also possible to set the trigger condition as a combination of the state change amounts of the mold data. In FIG. 6, the data is ANDed or ORed in a tabular form with the trigger condition of bit type data and the result of the state change amount of the word type data of the collected data.
The logical condition such as "trigger condition" is set. The time difference when setting the change amount can also be set.

Embodiment 6 FIG. In the second embodiment, the trigger condition setting unit 5 sets the trigger condition of the collected data as word-type data as shown in FIG. 3 to search for a match. It is also possible to set the trigger condition as a combination of the change amount conditions. In FIG. 7, a combination of the trigger condition of word type data and the result of the trigger condition of the state change amount of the word type data of the collected data as a logical condition is set as a trigger condition. The time difference when setting the change amount can also be set.

Embodiment 7 In the sixth embodiment, the trigger condition setting unit 5 sets the trigger condition by the combination of the word type data and the state change amount of the word type data in the collected data as shown in FIG.
Furthermore, it is possible to set a combination of the trigger conditions of the bit type data of the collected data as the trigger condition. In FIG. 8, the result of comparing the state change amount of word type data of a certain type of collected data with a certain value in a table format and a trigger condition of bit type data are mutually combined and the logical result thereof is used as a trigger condition. Make settings. The time difference when setting the change amount can also be set.

[0029]

As described above, according to the present invention, the ON / OFF value of the bit type data is used as the trigger point in the first embodiment, and the collected data before and after the ON / OFF value are displayed on the display screen. The progress before and after the ON / OFF timing of the operation command signal and the sensor, motor, etc. is clarified, and it becomes easy to analyze the cause of failure while watching the data read at the same time as the data before and after that timing. The work efficiency required for grasping is greatly improved.

Further, in the second embodiment, since the collected data before and after the value of the word type data as the trigger point is displayed on the display screen, the operation analog value of the plant, the capacity of the sensor, the motor, etc. are displayed. When it reaches a certain value, or before and after the timing when it becomes more than or less than a certain value, the progress before and after the timing becomes clear, and it becomes easy to analyze the failure factor while watching the data read at the same time as the data before and after that timing. The work efficiency required to grasp the operating status is greatly improved.

Further, in the third embodiment, since the collected data before and after the change amount of the word type data as the trigger point is displayed on the display screen, the change of the operation analog amount of the plant, the sensor, the motor, etc. When the amount of change in the capacitance reaches a certain value, or before and after the timing when it becomes more or less than a certain value, the cause of failure, etc. can be observed while looking at the data read before and after the timing. Will be easier to analyze and the work efficiency required to grasp the operating status will be greatly improved.

Furthermore, in the fourth embodiment, since the collected data before and after the combination of the bit type data and the word type data as the trigger point is displayed on the display screen, the combined operation of the plant operation signal and the analog value is performed. The ON / OFF state of sensors, motors, etc. and the progress before and after the timing can be clarified by the value of its capacity, making it easy to analyze the cause of failure while watching the data read at the same time as the data before and after that timing. The work efficiency required to understand the situation is greatly improved.

Further, in the fifth embodiment, since the collected data before and after the combination of the state change amount of bit type data and word type data as a trigger point is displayed on the display screen, the operation signal of the plant and the analog data are displayed. The progress before and after the timing is clarified by the combination of the value combination operation, ON / OFF of the sensor, motor, etc., and the variation of its capacity, and the cause of failure etc. can be seen while watching the data read before and after the timing. Analysis becomes easier,
The work efficiency required to grasp the operating status is greatly improved.

Further, in the sixth embodiment, since the collected data before and after the combination of the word type data and the state change amount of the word type data as the trigger point is displayed on the display screen, the analog value of the plant and its The progress before and after the timing is clarified due to the combined operation of the quantities and the combination of the capacity of the sensor, motor, etc. and the amount of change in the capacity, and it is easy to analyze the cause of failure while watching the data read before and after the timing. As a result, the work efficiency required to grasp the operation status is significantly improved.

Further, in the seventh embodiment, since the collected data before and after the combination of the bit type data, the word type data, and the state change amount of the word type data as the trigger points is displayed on the display screen, The progress before and after the timing due to the combination of the operation signal, the analog value, and the change in the amount, the ON / OFF of the sensor, the motor, etc., and the combination of the capacity and the amount of change in the capacity becomes clear, At the same time, it becomes easy to analyze the cause of failure while observing the read data, and the work efficiency required for grasping the operating status is greatly improved.

As a result, the trigger match condition file and the retrieved trigger are searched from the data file group based on the trigger condition in the collected data, the logical combination condition such as the state change amount of the bit type data or the word type data. By reading the collected data including before and after the points, the operating state of each data up to the trigger condition or the operating state after the trigger condition is confirmed, and the behavioral state and inconvenience of each drive unit for the failure analysis of the plant are confirmed. The so-called control status and abnormal state such as the operation history of the output circuit can be clarified, the efficiency of the work for identifying the cause of failure and studying the countermeasure is improved, and the practical effect is remarkably large.

[Brief description of the drawings]

FIG. 1 is a functional configuration diagram showing a failure analysis device according to the present invention.

FIG. 2 shows a trigger condition setting table of a trigger condition setting unit according to the first embodiment of the present invention.

FIG. 3 shows a trigger condition setting table of a trigger condition setting unit according to the second embodiment of the present invention.

FIG. 4 shows a trigger condition setting table of a trigger condition setting unit according to the third embodiment of the present invention.

FIG. 5 shows a trigger condition setting table of a trigger condition setting unit according to the fourth embodiment of the present invention.

FIG. 6 shows a trigger condition setting table of a trigger condition setting unit according to the fifth embodiment of the present invention.

FIG. 7 shows a trigger condition setting table of a trigger condition setting unit according to the sixth embodiment of the present invention.

FIG. 8 shows a trigger condition setting table of a trigger condition setting unit according to the seventh embodiment of the present invention.

FIG. 9 shows a schematic configuration example of a conventional system bus monitor device.

[Explanation of symbols]

1 controller, 2 collected data setting unit, 3 data collecting unit, 4 collected data file group, 5 trigger condition setting unit, 6 collected data file trigger condition matching search unit,
7 display data generation section, 8 search result file, 9 data display editing section, 10 CRT display.

Claims (8)

[Claims] 1. A mechanism for designating data to be collected from the data in the plant control controller, a mechanism for collecting the designated data at a fixed cycle, and a data file for storing the data collected at each collection timing. Group and fault condition in plant are defined by trigger conditions.
The trigger condition setting mechanism to be set, the trigger condition match detection mechanism that searches the data in the data file group according to the set trigger condition and identifies the data file that matches the above trigger condition, and the data detected by the above match detection mechanism A failure analysis device having a display data generation mechanism for generating a search result file by synthesizing a file and data files collected before and after the file, and a display data editing mechanism for performing processing for displaying data in the search result file . 2. The trigger condition setting mechanism defines a failure state in a plant by an ON / OFF value of bit type data or a logical combination thereof, and extracts desired data from the data file group. The failure analysis device according to claim 1, wherein 3. The trigger condition setting mechanism defines a fault state in a plant by a value of word type data or a logical combination thereof, and extracts desired data from the data file group. The failure analysis device according to claim 1. 4. The trigger condition setting mechanism defines a fault state in a plant by a state change amount of word type data or a logical combination thereof, and extracts desired data from the data file group. The failure analysis device according to claim 1, wherein 5. The trigger condition setting mechanism defines a fault condition in a plant by a combination of ON / OFF values of bit type data and values of word type data, and selects the desired state from the data file group. The failure analysis device according to claim 1, wherein data is extracted. 6. The trigger condition setting mechanism defines a failure state in a plant by a combination of ON / OFF values of bit type data and state change amount of word type data, and selects from the data file group. The failure analysis device according to claim 1, wherein desired data is extracted. 7. The trigger condition setting mechanism defines a failure state in a plant by a combination of word type data and a state change amount of word type data, and extracts desired data from the data file group. The failure analysis device according to claim 1, wherein 8. The trigger condition setting mechanism defines a failure state in a plant by a combination of an ON / OFF value of bit type data, a value of word type data, and a state change amount of word type data, The failure analysis device according to claim 1, wherein desired data is extracted from the data file group.