JPH11194820A - Fault analyzing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To retrieve a data file which meets trigger conditions from a data file group gathered up to alarm generation, and then make it possible to display it on a screen together with data before and after it if a fault occurs to a plant of iron and steel, chemicals, etc. SOLUTION: A data gathering part 3 gathers object data set in a gathered data setting part 2 from a plant controller 1 and generates a gathered data file group 4. According to an alarm and an elapsed time set in an alarm setting part 5, a data file group is limited and a trigger condition match detection par t9 detects a corresponding data file from the limited data file group according to the trigger conditions set in a trigger condition setting part 8 and the numbers of read files before and behind the retrieved file; and a display data generation part 10 generates a retrieval result file 11 by putting the retrieved file together with the data files before and behind it and a data display editing part 12 displays it on a CRT display unit 13.

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 plant such as a steel or chemical plant.

[0002]

2. Description of the Related Art FIG. 9 is a block diagram showing a conventional failure analyzer disclosed in Japanese Patent Application No. 7-338053.

In FIG. 9, reference numeral 1 denotes a controller which controls a plant and inputs various data. 2 denotes a collection data setting unit for selecting data items to be collected and setting a fixed period of the collection time. A data collection unit that collects various data from the controller 1 based on the settings of the collection data setting unit 2, a collection data file group 4 that stores and saves the collected various data in time series, and 8 analyzes the stored collection data. A trigger condition setting unit 14 for setting a condition to be used as a trigger when performing the operation, a trigger condition match search unit 14 for searching whether the trigger condition matches the collected data of the collected data file 4 based on the set trigger condition, and 10 for matching Display data for processing the collected data before and after the searched collected data that matches the collected data corresponding to the search result into CRT display data. A data generating unit, 11 is a search result file for storing collected data obtained by display processing, 12 is a data display editing unit for displaying, editing and outputting the collected data of the search result file 11 to a CRT, and 13 is a match search based on a trigger condition. It is a CRT display for displaying and outputting collected data of results.

FIG. 10 shows an example of the setting contents of the trigger condition setting section 8 in FIG.
FIG. 9 is a trigger condition setting table for setting a logical combination of OFF as a trigger condition and setting the number of times of reading of collected data before and after the collected data at the matched trigger point when the trigger conditions are matched.

Next, the operation of the above-described conventional failure analysis device 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 group of files corresponding to the collection time. Collect and store data sequentially.

An analysis method for the data collected as described above is defined by the trigger condition setting unit 8 for failure analysis. The trigger condition setting unit 8 sets trigger conditions in a table format as shown in FIG. As the setting contents,
When a certain collected data is turned on or off when viewed as bit data, a trigger condition is set, or when the AND result of the bit data of one collected data and the bit data of another collected data is turned on The setting is made using the combination of the logic of the bit type data as the trigger condition as shown in FIG. Furthermore, the number of readouts of collected data before and after a trigger point (time) at which a trigger condition is detected is set.

The trigger condition match detecting section 14 searches the collected data file group 4 for collected data that matches the trigger condition based on the setting contents of the trigger condition setting section 8. More specifically, the collected data stored in the collected data file group 4 is viewed in chronological order. As shown in the trigger condition setting table of FIG. 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 a trigger point, and the display data generation unit 10 generates an amount of collected data corresponding to the number of readouts before and after set in the trigger condition setting table of FIG. By C
Search result file 11 after processing into data for RT display
Is stored in The search result file 11 stores the collected data before and after the trigger point for all of the collected data items 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 13 in order to see the result of the matching search under the trigger condition.
Alternatively, the data display editing unit 12 performs display editing for CRT display, such as selecting only a desired collected data item and scrolling and displaying it.

[0010]

Since the conventional failure analysis system is configured as described above, a state occurring in the plant occurs suddenly, and a simple signal obtained from the plant can be obtained. It is effective if it can be expressed by a combination.

However, when investigating the cause of a failure that has occurred in a plant such as a steel or chemical plant, the events that have occurred in the plant until the failure and the order thereof are often important clues. For example, when an abnormality has occurred, its history is pursued, but the cause of the failure can be limited by pursuing a related abnormality up to the abnormality. In this case, it is difficult to express the sequence of events only by setting the trigger conditions used in the conventional failure analysis system, and it is difficult to specify the data up to the plant abnormality. This requires a great deal of labor and time to check the occurrence of the events and the order of occurrence in the collected data while setting the trigger conditions. There was such a problem.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and it is desirable that a failure analyzer sets an alarm which occurs in a plant, a time elapsed until then, and a trigger condition which is a data search condition. , Search the collected data file for abnormalities set as alarms, and trigger points that match the trigger conditions set from the data file from before the occurrence to the time of occurrence at the set time from the detected alarm occurrence It is an object of the present invention to provide a failure analysis apparatus which searches for a file having a specified alarm occurrence point and a data file storing a specified alarm occurrence point and a trigger point, and displays the combined data file before and after the data file on a screen.

[0013]

According to a first aspect of the present invention, there is provided a failure analysis apparatus which collects all or selected data in each controller for controlling a plant at a constant period,
Data file collecting means for storing data selectively collected at each collection opportunity as one data file;
Means to set an alarm by the signal that collects the abnormality that occurs in the plant, alone or in combination, and the state of each signal that is assumed to have appeared when a failure occurred Means for setting as a trigger condition by a combination of: an alarm occurrence search means for searching a data file that matches a set alarm from a collected data file group; and an alarm occurrence search means for a set time after an alarm occurs. Data file limiting means for limiting the data file at the time of occurrence, trigger condition matching searching means for searching a data file that matches a set trigger condition from a collected data file group, and alarm occurrence searching means One of the trigger conditions detected by the alarm occurrence data file and the trigger condition match search means Data files and the display data generating means for combining the data file that corresponds to the longitudinal reading content, is provided with a means for displaying the display data on the screen.

That is, in the failure analysis device of the first aspect,
By setting an alarm, a delay time, and a trigger condition, which are conditions for a failure analyst to search for desired data, data in which the set trigger condition occurs after a predetermined time elapses until an alarm occurs is obtained. It is possible to easily set the abnormalities that occur in the plant and the order in which they occur, and it is possible to easily limit the data files necessary for analyzing the cause of the failure from the collected data files, so that countermeasures against failures can be taken easily be able to.

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

Further, the alarm and trigger condition setting mechanism according to the third aspect of the present invention defines a fault condition in the plant by a word-type data value or a logical combination thereof and extracts desired data from a data file group. It is something to do.

The alarm and trigger condition setting mechanism according to the fourth aspect of the present invention defines a fault condition in the plant by a state change amount of word-type data or a logical combination thereof and desires from a data file group. It is designed to extract data.

The alarm and trigger condition setting mechanism according to the fifth aspect of the present invention defines a fault condition in the plant by a combination of an ON / OFF value of bit-type data and a value of word-type data. The desired data is extracted from the data.

The alarm and trigger condition setting mechanism according to the invention of claim 6 defines a fault condition in the plant by a combination of an ON / OFF value of bit data and a state change amount of word data. Desired data is extracted from a file group.

Further, the alarm and trigger condition setting mechanism according to the invention of claim 7 defines a fault condition in the plant by a combination of word-type data and a state change amount of the word-type data, and selects from the data file group. This is to extract desired data.

Further, the alarm and trigger condition setting mechanism according to the invention of claim 8 is adapted to determine a fault condition in the plant by determining an ON / OFF value of bit data, a value of word data, and a state change amount of word data. Desired data is extracted from a data file group defined by a combination.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 Hereinafter, a failure analysis device according to a first embodiment of the present invention will be described with reference to the drawings. In FIG. 1, reference numeral 1 denotes a controller which controls a plant and inputs various data. 2 denotes a collection data setting unit for selecting data items to be collected and setting a fixed period of collection time. A data collection unit that collects various data from the controller 1 based on the setting contents of the unit 2, a collection data file group 4 that stores and saves the collected various data in a time series, and 5 includes, for example, ON / OFF of bit type data. An alarm setting unit that defines an abnormal state of equipment in the plant, and sets the above-described alarm when analyzing stored collected data and the time elapsed from before the occurrence of the alarm until the occurrence of the alarm. Reference numeral 6 denotes an alarm occurrence search unit for searching whether or not an alarm has occurred in the collected data of the collection data file group 4 based on the set alarm. Reference numeral 7 denotes a history time set before the occurrence of the alarm detected by the alarm occurrence search unit 6. , A trigger condition setting unit for setting a trigger condition, and 9 a trigger condition for the collected data limited by the data file limiting unit 8 according to the set trigger condition. A trigger condition match search unit 10 for searching whether there is a match exists between the collected data corresponding to the result of detecting the occurrence of the alarm and the collected data corresponding to the result of the search for the trigger condition. A display data generation unit for processing collected data before and after the collected data searched for a match into data for CRT display; Shows processed collected data and stores the search result files, 12 search results data display editing unit for displaying edit output collected data to the CRT of the file 11, 1
Reference numeral 3 denotes a CRT display for displaying and outputting collected data obtained as a result of a match search under a trigger condition.

FIG. 2 shows the setting contents in the alarm setting section 5 and the trigger condition setting section 8 in FIG. 1, and is set as a logical combination of ON / OFF of bit type data.
9 is an alarm and trigger condition setting table for setting the history time before the occurrence of the alarm and the number of times of reading of collected data before and after the collected data of the trigger point that matches the trigger condition.

Next, the operation of the failure analyzer according to 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 group of files corresponding to the collection time. Collect and store data sequentially.

An analysis method for the data collected as described above is defined by the alarm setting unit 5 and the trigger condition setting unit 8 for failure analysis. The alarm setting unit 5 sets an alarm in a table format as shown in FIG. 2 and also sets a lapse time before the occurrence of the alarm. The trigger condition setting unit 8 similarly sets trigger conditions in a table format as shown in FIG. The alarm and trigger conditions can be set as alarm or trigger conditions when certain collected data is turned on or off when viewed as bit data, or when bit data of one collected data and another collected data are used. A logic combination of bit data is set as an alarm or trigger condition, as in the case where the result of AND of bit data is ON. Furthermore, it is possible to narrow down the trigger condition search targets by setting a delay time for searching for whether or not the trigger condition is matched after a predetermined time has elapsed from before the occurrence of the alarm and limiting a data file for searching the trigger condition. By setting the number of readouts of the collected data before and after the trigger point (time) at which the trigger condition was detected, the history before and after the data to be analyzed can be grasped.

The alarm occurrence search unit 6 searches the collected data file group 4 for collected data that matches the alarm based on the setting contents of the alarm setting unit 5, and if the alarm occurrence can be searched, the data file limiting unit 7 acquires the alarm occurrence time from the collected data, and limits the data file corresponding to the time obtained by subtracting the delay time set in the alarm setting unit 5 from the collected data file group 4.

The trigger condition matching search unit 9 searches the data files collected after the data file limited by the data file limiting unit 7 based on the setting contents of the trigger condition setting unit 8 for collected data matching the trigger condition. I will do it.

More specifically, the alarm occurrence search unit 6 and the trigger condition match search unit 9 look at the collected data stored in the collected data file group 4 in chronological order. As shown in the setting table, it is determined whether or not the logical combination of the bit type data matches the condition. If they match, the collected time is used as an alarm occurrence and trigger point. If they do not match, the collected data for the next collection time is determined. Search until the action matches.

When the data file limiting unit 7 detects collected data matching the trigger condition from the limited data files, the collected time is used as a trigger point, the data file searched for the occurrence of the alarm, the data file used as the trigger point, and The display data generation unit 10 processes the collected data in an amount corresponding to the number of readouts before and after the data set in the trigger condition setting table into data for CRT display, and stores the processed data in the search result file 11.

The search result file 11 stores the collected data at the time of occurrence of the alarm and the collected data before and after the trigger point for all the collected data items stored in the collected data file group. As a result, the collected data before and after including the collected data searched for the occurrence of the alarm and the trigger point to be analyzed are extracted. After that, it is displayed and output on the CRT display 13 in order to see the result of the matching search based on the alarm occurrence and the trigger condition. However, the data at the time of the alarm occurrence and the data before and after the trigger condition are scrolled or displayed. CR, such as selecting only the desired collected data item and scrolling it for display
The display editing for T display is performed by the data display editing unit 12.

Embodiment 2 In the first embodiment, in the alarm setting unit 5 and the trigger condition setting unit 8, as shown in FIG. 2, the collected data is set to an alarm and a trigger condition using bit-type data to perform a match search. Can be set as word-type data to set alarm and trigger conditions. That is, in FIG. 3, the data in a tabular form is compared with the result of magnitude comparison with a certain value or the result of magnitude comparison of word data between collected data with the result of magnitude comparison of another word data by word data. The logical conditions are set as alarm and trigger conditions. This makes it possible to analyze analog data.

Embodiment 3 FIG. In the second embodiment, the alarm setting unit 5 and the trigger condition setting unit 8 set the alarm and trigger conditions using word-type data and perform a match search on the collected data as shown in FIG. It is also possible to set the amount of change as an alarm and trigger condition. That is, in FIG. 4, the data is expressed in the form of a word in the form of a table, and the result of comparing the state change amount of certain collected data with a certain value and the logical condition between those results are set as alarm and trigger conditions. It should be noted that the time difference when setting the change amount can also be set. This makes it possible to analyze an analog data change amount.

Embodiment 4 FIG. In the first embodiment, the alarm setting unit 5 and the trigger condition setting unit 8 set the trigger condition with bit-type data for the collected data as shown in FIG. 2 and perform a match search. It is also possible to set alarm and trigger conditions as a combination of data and word type data. That is, in FIG. 5, data is represented in a tabular form by bit-type data and word-type data, and the result of magnitude comparison with a certain value, the magnitude comparison between collected data, the magnitude comparison of another data, and the like, or Logical conditions such as OR are set as alarm and trigger conditions.

Embodiment 5 In the first embodiment, the alarm setting unit 5 and the trigger condition setting unit 8 set the alarm and the trigger condition with bit-type data and perform a match search on the collected data as shown in FIG. It is also possible to set the alarm and trigger conditions as a combination of the amount of change in the state of the bit data and the word data. That is, in FIG. 6, the data is expressed in the form of a table in the form of bit-type data and the amount of change in the word-type data of the collected data, and the resulting logical conditions such as AND or OR are set as alarm and trigger conditions.
It should be noted that the time difference when setting the change amount can also be set.

Embodiment 6 FIG. In the second embodiment, the alarm setting unit 5 and the trigger condition setting unit 8 set the alarm and trigger conditions with word-type data and perform a match search on the collected data as shown in FIG. It is also possible to set an alarm and a trigger condition as a combination of conditions of the state change amount of word-type data. That is, in FIG. 7, the data is represented in a table form by the state change amount of the word-type data and the word-type data of the collected data, and a result obtained by combining the results as a logical condition is set as an alarm and trigger condition. It should be noted that the time difference when setting the change amount can also be set.

Embodiment 7 In the sixth embodiment, the alarm setting unit 5 and the trigger condition setting unit 8 set the alarm and trigger conditions for the collected data as shown in FIG. However, it is also possible to set a combination of bit-type data of collected data as alarm and trigger conditions. That is, in FIG. 8, the result of comparing the data in the form of a table with the word-type data and the amount of change in the state of the word-type data of a certain collected data with a certain value and the bit-type data are combined with each other, and their logical results are used as alarm and trigger conditions. Set as It should be noted that the time difference when setting the change amount can also be set.

[0037]

As described above, according to the present invention, by setting an alarm, a delay time, and a trigger condition, which are conditions for a failure analyst to search for desired data, a constant until an alarm is generated. Since the data with the trigger condition set after the lapse of time can be obtained, it is possible to easily set the abnormalities that occur in the plant and the order in which they occur, and to analyze the cause of the failure from the collected data files. Since the data file can be easily limited, a countermeasure against a failure can be easily taken.

In particular, according to the second aspect of the present invention, since the alarm occurrence state and the trigger point are defined by ON / OFF of the bit type data, the operation command signal of the plant and the ON / OFF timing of the sensor and the motor are defined. , It is possible to define a failure occurrence state that incorporates the transition of the state of the plant. As a result, it is easy to limit the collected data to determine the cause of the failure, and the efficiency of the analysis work is greatly improved.

According to the third aspect of the present invention, since the alarm occurrence state and the trigger point are defined by the value of the word-type data, the operation analog value of the plant and the capacity of the sensor, motor and the like become a certain value. In this case, it is possible to define the fault occurrence state including the transition of the state of the plant by using the case where the value becomes a certain value or more. As a result, it is easy to limit the collected data to determine the cause of the failure, and the efficiency of the analysis work is greatly improved.

According to the fourth aspect of the present invention, the alarm occurrence state and the trigger point are defined by the amount of change in the word-type data, so that the change in the analog operation amount of the plant and the change in the capacity of the sensor, motor, etc. When the quantity becomes a certain value, or when the quantity becomes more or less than a certain value, it becomes possible to define the fault occurrence state including the transition of the state of the plant. As a result, it is easy to limit the collected data to determine the cause of the failure, and the efficiency of the analysis work is greatly improved.

Further, according to the fifth aspect of the present invention, since the alarm occurrence state and the trigger point are defined by the combination of the bit data and the word data, the combination operation of the operation signal of the plant and the analog value, the operation of the sensor, Using the ON / OFF of the motor and the like and the value of its capacity, it is possible to define a fault occurrence state that incorporates the transition of the state of the plant. As a result, it is easy to limit the collected data to determine the cause of the failure, and the efficiency of the analysis work is greatly improved.

Further, according to the present invention, the alarm occurrence state and the trigger point are defined by a combination of the state change amounts of the bit type data and the word type data, so that the operation signal of the plant and the change of the analog amount are defined. It is possible to define a failure occurrence state including a transition of a state of a plant by using a combination operation, a combination of ON / OFF of a sensor or a motor, and a change amount of the capacity thereof. As a result, it is easy to limit the collected data to determine the cause of the failure, and the efficiency of the analysis work is greatly improved.

Further, according to the present invention, the alarm occurrence state and the trigger point are defined by a combination of the word-type data and the state change amount of the word-type data. It is possible to define a failure occurrence state including a transition of a state of a plant by using a combination operation or a combination of a capacity of a sensor or a motor and a change amount of the capacity. As a result, it is easy to limit the collected data to determine the cause of the failure, and the efficiency of the analysis work is greatly improved.

Further, according to the present invention, the alarm occurrence state and the trigger point are defined by the combination of the bit type data, the word type data and the state change amount of the word type data. It is possible to define a fault occurrence state that incorporates a state transition of a plant by using a combination operation of a value and a change in the amount, ON / OFF of a sensor or a motor, and a combination of the capacity and the change amount of the capacity. As a result, it is easy to limit the collected data to determine the cause of the failure, and the efficiency of the analysis work is greatly improved.

[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 an alarm and trigger condition setting table according to the first embodiment of the present invention.

FIG. 3 shows an alarm and trigger condition setting table according to the second embodiment of the present invention.

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

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

FIG. 6 shows an alarm and trigger condition setting table according to the fifth embodiment of the present invention.

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

FIG. 8 shows an alarm and trigger condition setting table according to the seventh embodiment of the present invention.

FIG. 9 shows a schematic configuration example of a conventional failure analysis device.

FIG. 10 shows a trigger condition setting table of a conventional failure analysis device.

[Explanation of symbols]

1 controller, 2 collected data setting section, 3 data collection section, 4 collected data file group, 5 alarm setting section, 6 alarm occurrence search section, 7 data file limitation section, 8 trigger condition setting section, 9 trigger condition matching search section, 10 display data generator, 11 search result file, 12 data display editor, 13 CRT display.

Claims (8)

[Claims] 1. A mechanism for designating data to be collected from data in a plant control controller, a mechanism for collecting designated data at regular intervals, and a data file group for storing data collected at each collection timing And an alarm setting mechanism that defines the abnormal state of equipment in the plant, an alarm occurrence search mechanism that searches the collected data files for whether the set alarm has occurred, and an alarm that has been set Data file limiting mechanism that limits the data file group after a certain period of time before performing, trigger condition setting mechanism that defines and sets the operating state in the plant, and data file limiting mechanism that is limited according to the set trigger condition A trigger condition that searches for data in a data file group and identifies a data file that matches the above trigger condition A match detection mechanism, and a display data generation mechanism that combines the data file detected by the alarm occurrence search mechanism with the data file detected by the trigger match detection mechanism and data files collected before and after the data file to generate a search result file. A failure analysis device including a display data editing mechanism for performing a process for displaying data in a search result file. 2. The alarm setting mechanism and the trigger condition setting mechanism define an operation state in a plant by an ON / OFF value of bit data and a logical combination thereof.
2. The failure analysis device according to claim 1, wherein desired data is extracted from the data file group. 3. The alarm setting mechanism and the trigger condition setting mechanism define an operation state in the plant by a word-type data value or a logical combination thereof, and extract desired data from the data file group. 2. The failure analysis device according to claim 1, wherein: 4. The alarm setting mechanism and the trigger condition setting mechanism define an operation state in the plant by a state change amount of word type data or a logical combination thereof, and select desired data from the data file group. The failure analysis device according to claim 1, wherein the failure analysis device is configured to extract the failure. 5. An alarm setting mechanism and a trigger condition setting mechanism according to claim 1, wherein the operation state in the plant is a bit type data O.
2. The failure analysis apparatus according to claim 1, wherein the data is defined by an N / OFF value, a word-type data value and a combination thereof, and desired data is extracted from the data file group. 6. An alarm setting mechanism and a trigger condition setting mechanism which define an operation state in a plant by an ON / OFF value of bit-type data, a state change amount of word-type data and a combination thereof, and 2. The failure analysis device according to claim 1, wherein desired data is extracted from the group. 7. The alarm setting mechanism and the trigger condition setting mechanism define an operation state in a plant by a value of word-type data, a state change amount of word-type data, and a combination thereof. 2. The failure analysis device according to claim 1, wherein desired data is extracted from the data. 8. The alarm setting mechanism and the trigger condition setting mechanism define an operation state in a plant by an ON / OFF value of bit data, a value of word data, a state change amount of word data, and a combination thereof. 2. The failure analysis device according to claim 1, wherein desired data is extracted from the data file group.