KR102073925B1 - Deterioration diagnosis apparatus - Google Patents

Abstract

It is an object of the present invention to be able to determine the abnormality of a heater more easily and more quickly.
The current measuring unit 103 measures the current supplied to the heater 111, and the control value obtaining unit 102 obtains a control value for controlling the heater 111 output from the control unit 113. The graph display control unit 106 displays a graph in which the points of the pair of control values and measurement values selected by the selection unit 105 are arranged on coordinates of a two-dimensional plane with the control values and measurement values as axes. It is displayed on the display unit 108. In addition, the range display control unit 107 superimposes the allowable range stored in the reference storage unit 101 on the graph displayed on the display unit 108.

Description

Deterioration diagnostic device {DETERIORATION DIAGNOSIS APPARATUS}

The present invention relates to a deterioration diagnostic apparatus for diagnosing deterioration of a heating apparatus having a heater.

In industrial processes, there are many processes for heating a material. In the process of such a heating, the heater (heater) is generally used. In addition, the temperature control system is used in the operation control of a heater. The temperature controller measures the temperature of the processing target (monitoring target) that the heater is heating by using a temperature sensor such as a thermocouple or a resistance thermometer. The measured temperature is numerically displayed in a temperature controller.

Further, in the temperature controller, the control output (MV value) is obtained according to the detected temperature (PV value) and the set temperature (SP value). The obtained control output is output to the heater manipulator by the electric power regulator or the like. In the heater manipulator, the driving current of 100 V from the commercial power supply is controlled in accordance with the control output and output to the heater. The temperature of the object to be processed is controlled by the heating of the heater controlled in this way. In addition, the temperature controller has an abnormality detection function, detects an abnormal temperature of a process target to be monitored, an abnormality of a temperature sensor, and the like, and externally outputs the detected abnormality event as event information to display an alarm (alarm). . For example, an alarm is displayed by the indicator which numerically displays temperature.

Moreover, in a temperature control system, abnormality of the heater itself, such as disconnection of a heater, is detected (refer patent document 1, 2). For example, the effective value power is obtained by measuring the current and voltage applied to the heater, the resistance value is further obtained from the relationship between the current and the voltage, and the deterioration of the heater is judged from the difference in the obtained resistance value and the degree of change (patent See Document 1). Moreover, heater deterioration is judged using the data which table | surfaced the measured output point of a control output and an electric current value (refer patent document 2).

[Patent Document 1] Japanese Patent No. 2683851 [Patent Document 2] Japanese Patent No. 3988942

However, in the above technique, first, measurement of the current flowing through the heater and the voltage applied to the heater is required. Moreover, in the above technique, calculation of parameters for abnormality diagnosis, such as resistance value, is complicated. In addition, the above-described technique has a problem in that it takes time to measure elapsed time and the like in order to investigate the time change of the resistance value. As described above, in the above-described technique, complicated calculation and measurement were required until the above judgment.

The present invention has been made to solve the above problems, and an object of the present invention is to enable a simpler and faster determination of a heater abnormality.

The deterioration diagnosis apparatus according to the present invention is a deterioration determination of a heating apparatus set from an upper allowable value and a lower allowable value of a current value with respect to a control value in a reference line indicating a normal characteristic of a heater constituting a heating apparatus that is a deterioration diagnosis target. To measure the current supplied to the heater in accordance with the control value acquired by the first storage section storing the allowable range for the control, the control value obtaining section configured to acquire the control value for controlling the heater, and the control value obtaining section. A current measurement section configured to acquire measured values, a second storage section for storing a pair of control values acquired by the control value acquisition section and measured values measured by the current measurement section in time series, and a pair corresponding to the received selection instruction. A selection unit configured to select a control value and a measured value from the second storage unit, and a pair of control values and measurement values selected by the selection unit. The display unit displays a first display control unit configured to display a graph arranged on the coordinates of a two-dimensional plane having one point as a control value and a measured value as an axis, and an allowable range stored in the first storage unit. And a second display control unit configured to superimpose the present graphs.

In the said degradation diagnostic apparatus, a 1st memory | storage part memorizes a reference line, and a 2nd display control part superimposes a reference line on the graph displayed on a display part.

In the deterioration diagnostic apparatus, a deviation calculation unit configured to obtain a deviation from a reference line between a pair of control values and a measurement value selected by the selection unit, and a time point and deviation of the deviation points calculated by the deviation calculation unit. It is provided with the 3rd display control part arrange | positioned on the coordinate of the two-dimensional plane to be displayed on a display part with the permissible range stored in the 1st memory part.

The deterioration diagnosis apparatus comprising: a deviation calculation unit configured to obtain a deviation from a reference line of a control value and a measurement value constituting the pair selected by the selection unit, and the pair selected by the selection unit by the first display control unit; After drawing the point by the control value and the measured value which were made | formed as the point of the form according to the magnitude of the deviation calculated | required by the deviation calculation part, the graph arrange | positioned on the coordinate of the two-dimensional plane which makes a control value and a measured value an axis | shaft. Is displayed on the display.

In the deterioration diagnosis apparatus, the reference line may be a line approximation of a heater characteristic indicating a relationship between a control value in a heater at a normal time and a corresponding current.

By the above description, according to this invention, the outstanding effect that the abnormality of a heater can be judged more easily more quickly is acquired.

FIG. 1: is a block diagram which shows the structure of the degradation diagnostic apparatus 100 in Embodiment 1 of this invention.
2 is an explanatory diagram showing a display example by the graph display control unit 106.
3 is a configuration diagram showing the configuration of the degradation diagnostic apparatus 100a according to the second embodiment of the present invention.
4 is an explanatory diagram showing a display example by the deviation display control unit 302.
5 is an explanatory diagram showing another display example by the graph display control unit 106.

EMBODIMENT OF THE INVENTION Hereinafter, embodiment of this invention is described with reference to drawings.

Embodiment 1

First, Embodiment 1 of this invention is demonstrated using FIG. FIG. 1: is a block diagram which shows the structure of the degradation diagnostic apparatus 100 in Embodiment 1 of this invention. The deterioration diagnosis apparatus 100 includes a reference storage unit (first storage unit) 101, a control value acquisition unit 102, a current measurement unit 103, a measurement storage unit (second storage unit) 104, A selection unit 105, a graph display control unit (first display control unit) 106, a range display control unit (second display control unit) 107, and a display unit 108 are provided. The deterioration diagnosis apparatus 100 enables diagnosis of deterioration by a user of a heating device composed of the heater 111 and the operation unit 112. The deterioration diagnostic apparatus 100 is an apparatus which supports deterioration determination of the heating apparatus by a user.

The reference storage unit 101 stores an allowable range (normal range) for deterioration diagnosis of the heater 111 and the operation unit 112. The allowable range is set from the upper allowable value and the lower allowable value of the current value supplied to the heater 111 in accordance with the control value given to the operation unit 112 (heating device) at the time of normal operation. The allowable range is used to determine deterioration by the user of the heater 111 and the operation unit 112 (heating device). In this case, the larger the control value, the wider the allowable range. In general, the smaller the control value, the smaller the acceptable range of the current value. Therefore, in the range where the control value is small, the width determined as abnormal is also narrowed, and in the range where the control value is large, the width determined as abnormal is widened.

For example, a reference line is created by using the continuously varying control values given for the heaters 111 and the heater characteristics indicating the change of the current in the heaters 111 at the time of normal corresponding to the control values. The heater characteristic itself may be used as the baseline. In addition, a heater line may be approximated and cut off as a reference line. Moreover, you may create a reference line by approximating the cut line by the discretely changing control value and the discretely changing current value in the heater 111 at the time of normal corresponding to this control value.

What is necessary is just to set a tolerance range from the upper permissible value and the lower permissible value of the electric current value with respect to the control value in this reference line. The heater 111 or the range between the upper permissible value line by the upper permissible value of the current value to the control value in the reference line and the lower permissible value line by the lower permissible value of the current value to the control value in the reference line. The operation part 112 is set to the permissible range which can be considered normal. The reference storage unit 101 may store the reference line used for setting the allowable range.

The control value acquisition part 102 acquires the control value for controlling the heater 111 (heating apparatus) which the control part 113 outputs. The control value is calculated by the control unit 113 from the measured value measured by the temperature measuring unit 114 and the set value that is set, and is output to the operation unit 112. The control unit 113 is, for example, a temperature controller. The operation unit 112 is configured of, for example, a well-known power regulator. The operation part 112 controls the drive current of 100V obtained from a commercial power supply by the said control value, and controls the heating operation by the heater 111. FIG. By this control, the current value flowing through the heater 111 is determined. The control value acquisition part 102 is a function part which acquires the above-mentioned control value output from the control part 113 (refer patent document 1).

The current measuring unit 103 measures the current supplied to the heater 111. For example, the current measuring unit 103 acquires an effective current value as a measured value. The current measuring unit 103 is composed of, for example, a well known current transformer. In the embodiment, the current measuring unit 103 is used for the alarm output in the control unit 113 which is a temperature controller. In this case, the current measuring unit 103 detects the drive current value to the heater 111 and outputs it to the control unit 113. The control unit 113 compares the preset alarm level with the detected value to determine the detected value. When the alarm level is exceeded, an alarm signal indicating an abnormality in the heating temperature is output. In addition, a measured value may be an average electric current value.

The measurement storage unit 104 stores, in time series, a pair of control values acquired by the control value acquisition unit 102 and measured values measured by the current measurement unit 103. In other words, the measurement storage unit 104 stores the measured values measured in time series at predetermined intervals in association with the control values when the measured values are measured. For example, when the current value is measured at five minute intervals, the pair of control value and measured value is stored in the measurement storage unit 104 at five minute intervals. In addition, a pair of the average value of the control value for one day and the average value of the measured value measured at 5-minute intervals is stored in the measurement storage unit 104 every day. In addition, the measurement storage unit 104 associates and stores the measured date and time information with a pair of control values and measured values.

The selection unit 105 selects, from the measurement storage unit 104, the paired control values and measurement values corresponding to the received selection instructions. For example, when a period is received as a selection instruction, a pair of control values and measured values to which the date and time information of the indicated period is associated is selected.

The graph display control unit 106 displays a graph in which the points of the pair of control values and measurement values selected by the selection unit 105 are arranged on coordinates of a two-dimensional plane with the control values and measurement values as axes. It is displayed on the display unit 108. In addition, the range display control unit 107 superimposes the allowable range stored in the reference storage unit 101 on the graph displayed on the display unit 108.

For example, as shown in FIG. 2, the graph display control unit 106 displays a graph by the selected control value and the measured value point 201 on the coordinates of the two-dimensional plane. In addition, the graph display control part 106 adds numbers to the point 201 in order of date and time, based on the date and time information in a pair of a control value and a measured value. For example, in FIG. 2, the pair of the average value of the control value for every day and the average value of the measured value are displayed for 8 days.

In addition, the range display control part 107 displays the permissible range which consists of the lower permissible value line 211 and the upper permissible value line 212 superimposed on the graph by the point 201. When the reference storage unit 101 stores the reference line, the range display control unit 107 displays the reference line 213 together with the allowable range.

In the display of the above-mentioned graph, since the latest point 201a in the display exceeds the lower permissible value line 211 in the allowable range, it can be determined that it is deteriorated. In addition, although the "7" is attached | subjected, it is in the permissible range, but the deviation from the reference line 213 is large. From this state, it can be judged that deterioration has progressed to some extent, and it can be determined that prophylactic maintenance is required.

As described above, according to the first embodiment, the abnormality of the heater can be judged more simply and more quickly.

Embodiment 2

Next, Embodiment 2 of this invention is described using FIG. 3 is a configuration diagram showing the configuration of the degradation diagnostic apparatus 100a according to the second embodiment of the present invention. The deterioration diagnosis apparatus 100a includes a reference storage unit (first storage unit) 101, a control value acquisition unit 102, a current measurement unit 103, a measurement storage unit 104, a selection unit 105, A graph display control unit (first display control unit) 106, a range display control unit (second display control unit) 107, and a display unit 108 are provided. These structures are the same as that of Embodiment 1 mentioned above.

In Embodiment 2, the deviation calculation part 301 and the deviation display control part (third display control part) 302 are newly provided.

The deviation calculation unit 301 calculates a deviation from the reference line between the paired control value and the measurement value selected by the selection unit 105.

The deviation display control part 302 arrange | positions the point of the deviation which the deviation calculation part 301 calculated on the coordinate of the two-dimensional plane which makes time and a deviation an axis, and is memorize | stored in the reference memory | storage part 101. Together with the display unit 108. The deviation display control part 302 displays the graph by the point 401 of the deviation of the selected measured value on the coordinate of the 2D plane displayed on the display part 108, for example as shown in FIG. In this example, the date is on the horizontal axis.

Moreover, the deviation display control part 302 displays the tolerance range which consists of the lower tolerance value line 411 and the upper tolerance value line 412 superimposed on the graph by the point 401. FIG.

In the display of the above-mentioned graph, since the point 401a of the eighth day which is the latest in display exceeds the lower permissible value line 411 of a permissible range, it can be judged that it is deteriorated. In addition, although the 7-day point is in an allowable range, the deviation is large. From this state, it can be judged that deterioration has progressed to some extent, and it can be determined that prophylactic maintenance is required.

In addition, in the structure of Embodiment 2, it is also possible to display on the display part 108 by another graph as shown in FIG. Although FIG. 5 arrange | positions the point of a selected control value and a measured value on the coordinate of the 2D plane which took the control value on the horizontal axis and the measured value on the vertical axis like FIG. 2, the magnitude | size of each point is made to the deviation calculation part 301. It draws and displays in size (large deviation is large) according to the deviation computed by. 5 shows an example in which a pair of the average value of the control value per day and the average value of the measured value are displayed for 7 days. Here, the larger the deviation from the reference line 213 is, the larger the circle appears. For example, the point 201b is outside the permissible range and is represented by the largest circle because the deviation from the reference line 213 is the largest.

In this way, the monitor can grasp the deviation of the point sensibly while checking the control value and the measured value of each point, and can easily grasp the progress of deterioration. On the other hand, in addition to drawing the magnitude | size of a point by the magnitude | size according to a deviation, you may draw with coloration (gradation) according to the deviation, In other words, you may draw with the point of the form according to the deviation.

As described above, according to the second embodiment, the abnormality of the heater can be judged more simply and more quickly.

As described above, in the present invention, the display unit displays a graph in which the points of the pair of control values and the measured values selected by the selection unit are arranged on the coordinates of the two-dimensional plane with the control values and the measured values as axes. Mark on the graph and overlay the allowable range on this graph. As a result, according to the present invention, the user can quickly determine the deterioration by visually viewing the display, and can determine the abnormality of the heater more easily and more quickly.

Here, the reference line will be described in more detail. As a reference line, you may use what approximated the heater characteristic. The approximate reference line is composed of one or more line segments (primary equations) on the coordinates of a two-dimensional plane with the control value and the measured value as axes. In this way, by setting the allowable range using the approximated reference line, the amount of data held as the allowable range can be very small. Since the reference line is composed of a combination of straight lines (primary equation), the allowable range is also composed of a combination of straight lines (primary equation), and the data amount is very small.

For example, what is necessary is just to measure the heater characteristic of the heater at the time of normality, and to calculate | require a reference line by cut line approximation from the measured heater characteristic. What is necessary is just to make a reference line by providing a predetermined number of set points (break points) on the obtained curve of a heater characteristic under predetermined conditions, and connecting the provided set points by a straight line (line segment). In addition, at a predetermined number of measurement points, a current value is obtained by measuring a current with respect to a control value in a heater (heating device) in a normal state, and a set point is determined by setting a predetermined number of control values and a current value. What is necessary is just to set it as a reference line by connecting the set points to be straight.

Nine set points are set on the curve in the coordinates of the two-dimensional plane with the control and measured values as the axes. On the other hand, at least, the set point is set to the minimum value of the control value and the maximum value of the control value, respectively. Next, a reference line is created by connecting two adjacent set points to each other in a straight line. For example, nine set points are connected in order to create a reference line. The reference line is composed of eight line segments.

In addition, you may set the set point for creating a reference line as shown below. First, in the coordinates of a two-dimensional plane having the control value and the measured value as axes, a first approximation line for arranging set points corresponding to the minimum value and the maximum value of the control value in the curve representing the heater characteristic and connecting them Set. Further, a predetermined upper allowable value line and a lower allowable value line are set for the first approximation line. The region sandwiched between the upper allowable value line and the lower allowable value line is a candidate for the allowable range.

As described above, the first approximation line is determined by the two set points, and in the state where the candidate of the allowable range is set, the curve falls within the candidate of the allowable range, and the maximum deviation between the first approximation line and the curve is preset. Determine what is smaller than the allowable deviation. When the curve falls within the allowable range and the maximum deviation is smaller than the allowable deviation, the first approximation line is taken as the reference line.

On the other hand, when a region where the curve exceeds the allowable range occurs, the curve and the deviation in the positive direction of the point and the measured value where the curve and the deviation become the maximum value in the negative direction of the measured value with respect to the first approximation line. Find the point that becomes the maximum value.

Next, a new set point is added on the curve in the two locations obtained. Next, a new 2nd approximation line which connects four control points by adding is set. In addition, a predetermined upper allowable value line and a lower allowable value line are set for the new second approximation line.

It is confirmed that the curve enters the allowable range by the upper allowable value line and the lower allowable value line obtained in this way, and the maximum deviation between the second approximation line and the curve is smaller than the allowable deviation. For example, at this stage, the second approximation line is referred to as the reference line because the curve falls within the allowable range and the maximum deviation between the second approximation line and the curve is smaller than the allowable deviation.

According to the above-described creation method of the reference line, by setting the maximum deviation appropriately, the allowable range in which practical deterioration determination is possible can be set without unnecessarily increasing the set point. On the other hand, depending on the setting conditions of the allowable deviation, the approximation curve can be determined only by comparing the allowable deviation and the maximum deviation without performing comparison with the allowable range.

In addition, you may create a reference line as shown below. First, in a normal heater (heating apparatus), a plurality of control values are set within the minimum and maximum range of control values, and the heater current value is measured at each set control value. For example, the control value is changed to 10% width in the range of 0 to 100%, and the heater current value is measured in each control value. Using the control points obtained as a result of this measurement and the plurality of set points by each heater current value, the cut line connecting the adjacent set points in a straight line is a reference line approximating the heater characteristics.

In addition, this invention is not limited to embodiment described above, It is clear that many deformation | transformation and combination are possible for those skilled in the art within the technical idea of this invention.

100: deterioration diagnostic apparatus 101: reference storage unit (first storage unit)
102: control value acquisition unit 103: current measurement unit
104: measurement storage section (second storage section) 105: selection section
106: graph display control unit (first display control unit)
107: range display control unit (second display control unit)
108: display portion 111: heater
112: operation unit 113: control unit
114: temperature measuring unit

Claims (5)

Deterioration diagnostic device,
To store the allowable range for the deterioration determination of the heating device set from the upper permissible value and the lower allowable value of the current value to the control value in the reference line indicating the characteristic at the time of the heater constituting the heating device to be deteriorated diagnosis target The first storage unit,
A control value acquisition unit configured to acquire a control value for controlling the heater;
A current measuring unit configured to measure a current supplied to the heater according to a control value obtained by the control value obtaining unit, and obtain a measured value;
A second storage unit for storing a pair of control values acquired by the control value acquisition unit and measured values measured by the current measurement unit in time series;
A selection unit configured to select a pair of control values and measured values corresponding to the received selection instruction from the second storage unit;
A first display configured to display, on a display unit, a graph in which points formed by pairs of control values and measured values selected by the selection unit are arranged on coordinates of a two-dimensional plane with the control values and the measured values as axes; With the control unit,
A second display control unit configured to display an allowable range stored in the first storage unit superimposed on the graph displayed on the display unit;
A deviation calculator configured to calculate a deviation from the reference line between the paired control value and the measured value selected by the selection unit;
A third display control unit configured to arrange the points of the deviation calculated by the deviation calculation unit on coordinates of a two-dimensional plane with time and deviation as axes and display the display unit together with the allowable range stored in the first storage unit;
Deterioration diagnostic apparatus comprising a. The method of claim 1,
The first storage unit stores the reference line,
The second display control unit is configured to display the reference line superimposed on the graph displayed on the display unit.
Deterioration diagnostic apparatus, characterized in that. delete Deterioration diagnostic device,
To store the allowable range for the deterioration determination of the heating device set from the upper permissible value and the lower allowable value of the current value to the control value in the reference line indicating the characteristic at the time of the heater constituting the heating device to be deteriorated diagnosis target The first storage unit,
A control value acquisition unit configured to acquire a control value for controlling the heater;
A current measuring unit configured to measure a current supplied to the heater according to a control value obtained by the control value obtaining unit, and obtain a measured value;
A second storage unit for storing a pair of control values acquired by the control value acquisition unit and measured values measured by the current measurement unit in time series;
A selection unit configured to select a pair of control values and measured values corresponding to the received selection instruction from the second storage unit;
A first display configured to display, on a display unit, a graph in which points formed by pairs of control values and measured values selected by the selection unit are arranged on coordinates of a two-dimensional plane with the control values and the measured values as axes; With the control unit,
A second display control unit configured to display an allowable range stored in the first storage unit superimposed on the graph displayed on the display unit;
A deviation calculator configured to calculate a deviation from the reference line of the paired control value and the measurement value selected by the selection part
And
The control is performed by the first display control unit after drawing the points of the pair of control values and the measured values selected by the selection unit to the points of the form according to the magnitude of the deviation obtained by the deviation calculation unit. And a graph arranged on a coordinate of a two-dimensional plane having a value and the measured value as an axis. The method according to claim 1 or 2,
The reference line approximates a heater characteristic representing a relationship between a control value in the heater at the time of normal and a corresponding current.
Deterioration diagnostic apparatus, characterized in that.

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