WO2021199429A1 - 制御装置及び異常検知方法 - Google Patents

制御装置及び異常検知方法 Download PDF

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Publication number
WO2021199429A1
WO2021199429A1 PCT/JP2020/015334 JP2020015334W WO2021199429A1 WO 2021199429 A1 WO2021199429 A1 WO 2021199429A1 JP 2020015334 W JP2020015334 W JP 2020015334W WO 2021199429 A1 WO2021199429 A1 WO 2021199429A1
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value
time
measured value
abnormality detection
output
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PCT/JP2020/015334
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English (en)
French (fr)
Japanese (ja)
Inventor
凌太 池田
木原　健
成田　貴光
佑磨 細田
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理化工業株式会社
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Priority to PCT/JP2020/015334 priority Critical patent/WO2021199429A1/ja
Priority to JP2022511482A priority patent/JP7266169B2/ja
Priority to CN202080094099.XA priority patent/CN115004856B/zh
Publication of WO2021199429A1 publication Critical patent/WO2021199429A1/ja

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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating

Definitions

  • the present invention relates to a control device and an abnormality detection method.
  • Patent Document 1 and Patent Document 2 disclose conventional techniques for detecting disconnection of a heater in such a temperature control device.
  • Patent Document 1 As a method of detecting disconnection, there is a method of determining disconnection or the like based on the measured current value by providing a current measuring unit.
  • Patent Document 1 also belongs to this category.
  • Patent Document 2 there is also a disconnection detection method that does not require a current measuring unit, and Patent Document 2 belongs to this method.
  • the maximum slope of the measured value PV in the normal state is used as a threshold value, and when the maximum slope R of the measured PV becomes smaller than the threshold value (the maximum slope of the measured value PV in the normal state), the heater is used. It is judged that the disconnection has occurred.
  • the technique of Patent Document 2 it is advantageous in that the current measuring unit can be eliminated, but there is a problem that it takes time to detect the disconnection.
  • the present invention is an abnormality detection method that does not require a current measuring unit, and is an abnormality detection method capable of shortening the time until disconnection detection as compared with the conventional case, and a control device using the abnormality detection method.
  • the purpose is to provide.
  • (Structure 1) It is a control device that calculates the operation amount for controlling the control target based on the measured value and the target value, and the control is determined based on the measured value obtained when a predetermined operation amount is input at the reference time.
  • a storage unit that stores the wasted time and a reference value determined based on the measured value obtained when a predetermined manipulated variable is input at the reference time, and an abnormality detection start output in which the manipulated variable is a threshold. It is characterized by including a notification output unit that outputs abnormal state information based on the comparison result of the value based on the measured value and the reference value after the lapse of the dead time from the start time of abnormality detection which is the time when the abnormality is exceeded. Control device.
  • the reference value is a reference change rate based on the change rate of the measured value determined based on the measured value obtained when a predetermined operation amount is input at the reference time, and the waste time from the start time of the abnormality detection.
  • (Structure 6) It is a control device that calculates the operation amount for controlling the control target based on the measured value and the target value, and the control is determined based on the measured value obtained when a predetermined operation amount is input at the reference time.
  • a disconnection alarm when the value based on the measured value is equal to or less than the disconnection reference value after the lapse of the waste time from the time when the storage unit that stores the waste time and the operation amount exceeds the threshold value of the abnormality detection start output.
  • a control device including a notification output unit for outputting a signal.
  • An abnormality detection method comprising: a step of outputting abnormal state information based on a comparison result of a value based on a measured value and the reference value after the elapse of the dead time from a time point.
  • the reference value is a reference change rate based on the rate of change of the measured value determined based on the measured value obtained when a predetermined manipulated variable is input at the reference time, and when the abnormality detection start output is exceeded.
  • the value based on the measured value is equal to or less than the disconnection reference value after the step of predetermining the waste time of the obtained control and the time when the operation amount exceeds the threshold value of the abnormality detection start output and after the lapse of the waste time.
  • An abnormality detection method including a step of outputting a disconnection alarm.
  • the present invention in the abnormality detection method that does not require a current measuring unit, it is possible to shorten the time until the disconnection is detected as compared with the conventional method.
  • Flow chart showing the outline of the abnormality detection process in the embodiment The figure which shows the experimental result about the abnormality detection processing of the temperature control apparatus of embodiment
  • the figure which shows the experimental result about the abnormality detection processing of the temperature control apparatus of embodiment Flowchart showing the outline of disconnection detection processing
  • the figure which shows the simulation result about anomaly detection processing The figure which shows the simulation result about anomaly detection processing
  • the figure which shows the simulation result about anomaly detection processing The figure which shows the simulation result about anomaly detection processing
  • FIG. 1 is a block diagram showing an outline of a configuration of a temperature control device (an example of a control device) according to an embodiment of the present invention.
  • the temperature control device 1 of the present embodiment is a device for controlling the temperature of the control target 2, and here, a device that controls the temperature of the temperature control target 22 heated by the heater 21 will be described as an example.
  • the temperature control device 1 controls the temperature of the controlled object 2 by PID control based on the deviation between the target value SV and the measured value PV (measured value by the temperature measuring unit 23) of the controlled object.
  • the temperature control of the control target 2 is performed by on / off control of a switching element (not shown in particular) provided in the power supply line to the heater 21 based on the operation amount MV calculated by the PID control.
  • the temperature control device 1 of the present embodiment detects disconnection of the heater 21 and outputs information (abnormal state information) based on the detection.
  • the temperature control device 1 includes a calculation unit 11, a storage unit 12, an input unit 13, and an output unit 14 as a rough configuration thereof.
  • the calculation unit 11 The PID calculation unit 111 that calculates the manipulated variable MV by the PID calculation based on the deviation between the target value SV and the measured value PV of the controlled object, and PID constant tuning unit 112 that calculates the PID constant for PID calculation, As will be described below, the rate of change PV d of the measured value and the reference rate of change after the lapse of waste time from the time when the operation amount MV exceeds the threshold value “abnormality detection start output”. Notification output unit 113 that outputs abnormal status information based on the comparison result of It has. Although the configurations are described separately for each function in FIG. 1, it does not necessarily indicate that they are divided into these configurations in terms of hardware.
  • the arithmetic unit 11 publicizes PLC, MCU, microcomputer, and the like.
  • Each configuration may be implemented in software by being configured using the above devices.
  • each configuration is implemented by software as an example.
  • each configuration may be configured as hardware, for example, one configured by using FPGA or the like, one configured by ASIC or the like as dedicated hardware, or the like.
  • the storage unit 12 stores each threshold value and reference value described below, the PID constant obtained in the self-tuning process by the PID constant tuning unit 112, waste time information, the inclination value at the time of reference, and the like.
  • the temperature control device 1 has a self-tuning function that automatically calculates a PID constant suitable for a control target and control conditions. Since the self-tuning process itself is a technique that has been used conventionally, detailed description here is omitted, but it is appropriate based on the measured value PV obtained for the input with the operation amount as 100%. It calculates the PID constant.
  • the dead time (the time from the time when the change occurs in the input to the time when the change appears in the output) and the rate of change of the measured value PV can be obtained, and this is the dead time. It is stored in the storage unit 12 as information and a tilt value at the time of reference.
  • the measured value PV is within this range based on the data when the measured value PV is in the range of 5% to 95% with respect to the target value SV.
  • the average slope of the measured value PV is defined as the “reference tilt value”.
  • the “slope value at the reference time” is not limited to this, and any information indicating the rate of change of the output obtained when a predetermined manipulated variable is input may be used.
  • the maximum slope of the measured value PV may be set to ". It may be the "inclination value at the reference time” or the like.
  • the “reference time inclination value” is a measured value / time, and the unit of the reference time inclination value in the present embodiment is ° C./min.
  • the input unit 13 receives various settings from the user and inputs such as operation instructions.
  • the input unit 13 is composed of an operation unit for which the user directly inputs and operates, a receiving unit for receiving data input from an external device, and the like.
  • the output unit 14 outputs information to the user, and is composed of, for example, various display devices, speakers, various warning lights, a transmission unit that outputs data to an external device, and the like.
  • the temperature control device 1 of the present embodiment has a function of detecting disconnection of the heater 21 and outputting information (abnormal state information) based on the detection.
  • the control waste time and the reference value determined based on the measured value obtained when a predetermined operation amount is input in a state where there is no abnormality in the device (or when the device is in a preferable state).
  • the “reference value” based on the rate of change of the measured value is acquired in advance as the reference value.
  • the abnormal state information is output based on the comparison result between this and the reference value.
  • the abnormal state information is output based on the comparison result between the change rate PV d of the measured value PV and the reference change rate determined based on the inclination value at the reference time. That is, it is determined whether or not there is an abnormality in the device depending on how much the rate of change of the measured value PV (inclination of PV) has changed as compared with the state where there is no abnormality in the device.
  • the processing operation of the temperature control device 1 relating to the feature will be described with reference to the flowchart of FIG.
  • the process of FIG. 2 is executed by the calculation unit 11 while reading and writing data to and from the storage unit 12 as needed. That is, here, the PID calculation unit 111, the PID constant tuning unit 112, and the notification output unit 113 are implemented as software as an example.
  • TDA is a flag indicating abnormal state information (step 201).
  • a judgment is made in three stages of "no abnormality”, "inspection notification”, and "disconnection detection”.
  • “No abnormality” is a state in which it is determined that there is no problem with the device, and the TDA value corresponds to 1.
  • the "inspection notice” is a notice that urges maintenance because performance has deteriorated, although it has not led to a failure.
  • the value of TDA corresponds to 2.
  • “Disconnection detection” is a state in which disconnection is detected, and the TDA value is 3. When a disconnection is detected, an alarm is issued and control stop processing is performed.
  • the operation amount MV is input (the value of the operation amount MV increases) by starting the temperature control process for the temperature control target 2.
  • the “abnormality detection start output” is a threshold value for determining the start of the abnormality detection process described in the present embodiment, is set at 80% in the present embodiment, and is stored in the storage unit 12.
  • PV d is the rate of change in temperature (differential value of PV) of the temperature control target 22 measured by the temperature measuring unit 23.
  • the "disconnection reference value” is a threshold value for determining a disconnection, and is set by, for example, multiplying the "reference tilt value” by a coefficient or subtracting a predetermined deviation amount (constant (absolute value) value). Of course, it may be set to.).
  • the coefficient is 0, and therefore the "disconnection reference value" is 0 ° C./min.
  • the disconnection reference value itself may be set in the storage unit 12, or a value necessary for calculation of a coefficient, a deviation amount, or the like is set in the storage unit 12, and the “inclination value at the time of reference” is used. It may be something like calculating a disconnection reference value. Further, the disconnection reference value itself may be set by the user, or a coefficient, a deviation amount, or the like for calculating the disconnection reference value may be set by the user.
  • step 203 if PV d does not exceed the disconnection reference value (that is, the slope of PV is not positive), the loop processing of steps 203 and 211 is performed.
  • step 211 it is determined whether or not the dead time L ⁇ 1.2 has elapsed from the time when the input of the operation amount MV is started. Since the output (PV) cannot be obtained until the lapse of a dead time after the operation amount MV is input, this time is waited. It should be noted that 1.2 times is the one with a margin, and the method of taking the margin can be arbitrarily set based on the control target, the design concept, etc. (it is also possible not to take the margin).
  • Step 211 If PV d does not exceed the disconnection reference value even after 1.2 L has elapsed from the time when the input of the operation amount MV is started, 3 is substituted for TDA and the disconnection alarm is output (step 211). : Yes ⁇ Step 212). Even though more than a waste time has passed since the operation amount was input, the PV tilt is not positive (no output), so it is judged to be a disconnection. be.
  • the “output of the disconnection alarm” is, in the present embodiment, the red lighting and the output of the warning sound of the corresponding warning light (LED as the output unit 14).
  • control stop processing and the like are performed together with the output of the disconnection alarm.
  • step 203 if the PV d exceeds the disconnection reference value as a result of the determination in step 203, the loop processing in steps 206 and 207 is performed. In the loop processing of steps 206 and 207, the processing of steps 204 and 205 is also performed.
  • step 206 it is determined whether or not PV d exceeds the “reference rate of change 1”.
  • the "reference rate of change 1" is (one of) a threshold value for determining the state of the device, and is set by a value obtained by multiplying the "reference tilt value” by a coefficient, a value obtained by subtracting a predetermined deviation amount, or the like. .. In this embodiment, the coefficient is 0.3 (30%).
  • the reference change rate 1 itself may be set in the storage unit 12, or values necessary for calculation of the coefficient, deviation amount, etc. are set in the storage unit 12, and the “inclination value at the time of reference” is set. It may be such that the reference change rate 1 is calculated from. Further, the reference change rate 1 itself may be set by the user, or a coefficient, a deviation amount, or the like for calculating the reference change rate 1 may be set by the user.
  • the abnormality detection end output itself may be set in the storage unit 12, or values necessary for calculation such as a coefficient and a deviation amount are set in the storage unit 12, and the “abnormality detection start output” is used. It may be something like calculating the abnormality detection end output. Further, the user may be made to set the abnormality detection end output itself, or the user may be made to set a coefficient, a deviation amount, or the like for calculating the abnormality detection end output.
  • step 204 is the same process as that of step 211 described above. If 1.2L has not elapsed since the input of the operation amount MV was started, step 205 is skipped, and after 1.2L has elapsed, output based on the TDA value is performed in step 205. Since 2 is input to the TDA in step 201, the value of the TDA here is 2.
  • the output based on the TDA value in step 205 is the yellow lighting of the LED as the output unit 14 in the present embodiment.
  • the PV d does not reach the "reference rate of change 1" after a lapse of more than a waste time after the operation amount is input, the failure has not occurred but the performance has deteriorated (for example, the heater 21). It is judged that (deterioration, etc.) is observed, and a notification (LED is lit in yellow) prompting maintenance is given.
  • step 206 Yes ⁇ step 208.
  • step 208 1 is assigned to TDA. As described above, it indicates "no abnormality”.
  • step 209 output based on the value of TDA is performed.
  • the “output based on the TDA value (1)” is, in the present embodiment, the green lighting of the LED as the output unit 14. In this embodiment, if a PV d having a value 0.3 times the inclination value at the reference time is obtained, it is an example of determining that the range is normal.
  • Step 210 following step 209 is the same discrimination process as step 207 described above, and when the value of the operation amount MV is not equal to or less than the “abnormality detection end output”, the process of step 209 (lit in green) is performed. continue.
  • the process of step 209 (lit in green) is performed.
  • “reference change rate 1" is reached even once from the start of abnormality detection, "no abnormality” is output, and if not, “no abnormality” is output.
  • “Inspection notification (or disconnection alarm)” will be output. That is, “the abnormal state information indicating an abnormality is output when the rate of change of the measured value never reaches the reference rate of change between the start of abnormality detection and the elapse of a predetermined time or more.
  • the process of "doing” is performed.
  • step 207 or 210 if the value of the manipulated variable MV is equal to or less than the "abnormality detection end output", the process returns to step 201. That is, when the value of the operation amount MV becomes equal to or less than the "abnormality detection end output", the abnormality detection process is temporarily terminated. When the value of the operation amount MV reaches the abnormality detection start output again (step 202), the abnormality detection process described above is restarted. Even after the execution of the abnormality detection process is completed, the output based on the TDA information from the output unit 14 (in this example, the LED is lit) may be continued.
  • FIG. 3 is a diagram showing an experimental result (at the time of start-up) regarding the abnormality detection process of the temperature control device 1 of the present embodiment.
  • the upper graph of FIG. 3 shows the change of the manipulated variable MV and the measured value PV with the passage of time, and the lower graph shows the PV d which is the slope of the measured value PV and the slope value at the reference time. And the standard rate of change of 1 is shown.
  • the conditions of the experiment are as follows (the setting of each threshold value is as described above).
  • Reference tilt value 36.9 (° C / min)
  • Waste time L 22 (sec)
  • PV d exceeds the “reference rate of change 1” before 50 (sec), and in reality, anomaly detection is performed at an earlier stage than 75 (sec). It can be carried out. Further, in the past, only the presence or absence of disconnection (only binary value) was determined, but in the present embodiment, a stepwise determination is possible.
  • FIG. 4 is an experiment under basically the same conditions as FIG. 3, and is a diagram showing the results of an experiment simulating the case where a disconnection occurs when the control is in a steady state.
  • the upper graph of FIG. 4 shows the change of the manipulated variable MV and the measured value PV with the passage of time, and the lower graph shows the PV d which is the slope of the measured value PV and the slope value at the reference time. And the disconnection reference value is shown.
  • the MV or PV is in a steady state, the PV starts to decrease due to the disconnection.
  • feedback is applied and the MV starts to rise, but the PV continues to fall because the wire is broken.
  • the presence or absence of disconnection is determined based on whether or not the PV is changed when twice the integration time elapses after the manipulated variable MV becomes 100%. In this example, the alarm was not output until 2500 (sec) was exceeded.
  • FIGS. 6 to 8 Similar to FIG. 4, the upper graph shows the change of the manipulated variable MV and the measured value PV with the passage of time, and the lower graph shows the slope of the measured value PV PV d. The slope value at the time of reference and the reference change rate 1 are shown.
  • the conditions used in the simulations of FIGS. 6 to 8 are as follows (settings other than the following are the same as those of the experiment of FIG. 4).
  • FIG. 6 is a simulation result simulating the case where the device is normal.
  • the abnormality detection is started.
  • the reference rate of change 30.8 * 0.3 ⁇ 9.2
  • the detection can be performed faster.
  • FIG. 7 is a simulation result simulating an abnormality of the device (a state in which the deterioration of the heater has progressed).
  • the abnormality detection is started.
  • the reference change rate 30.8 * 0.3 ⁇ 9
  • a notification prompting maintenance LED lights in yellow
  • a notification prompting maintenance LED lights in yellow
  • a notification prompting maintenance LED lights in yellow
  • PV lights in yellow is once given, but when it exceeds 80 sec in FIG. 7 after that, PV d exceeds the reference rate of change, so there is no abnormality at this point. It changes to the notification (LED lights up in green).
  • the user can say that the device is in a state where there is no problem for the time being, but it can be recognized that the device is deteriorating.
  • FIG. 8 shows the result of a simulation simulating the case where a disconnection occurs when the control is in a steady state.
  • the PV starts to decrease due to the disconnection.
  • feedback is applied and the MV starts to rise, but the PV continues to fall because the wire is broken.
  • the MV continues to rise, and when the MV reaches the abnormality detection start output (80%), the abnormality detection is started.
  • the temperature control device 1 of the present embodiment it is an abnormality detection method that does not require a current measuring unit, and it is possible to shorten the time until the disconnection is detected as compared with the conventional method.
  • stepwise abnormal state information in this embodiment, "no abnormality”, “inspection notification”, “disconnection detection”
  • the disconnection can be basically detected only at the time of temperature rise (because the maximum inclination of PV cannot be obtained).
  • the temperature control device 1 of the present embodiment it is possible to detect disconnection even when the temperature is not raised, as described above.
  • the abnormal state information three stages of "no abnormality", "inspection notification”, and “disconnection detection” are taken as an example, but it may be determined in more stages.
  • the "reference rate of change” is multiplied by 0.3 on the "reference tilt value”, but the "reference tilt value” is 0.2, 0.4, 0.6. , 0.8, etc. may be multiplied by each, and a plurality of "reference rate of change” may be defined, and the abnormality may be output in terms of degree.
  • FIG. 5 is a flowchart showing an outline of a process of only detecting disconnection at startup. After the start of the temperature control process for the temperature control target 2 (step 501), it is determined whether or not the manipulated variable MV exceeds the abnormality detection start output (step 502). Next, wait for the elapse of 1.2 L after the operation amount MV exceeds the abnormality detection start output (step 503). The processes of steps 502 and 503 are the same as those of steps 202 and 211 of FIG.
  • steps 504 and 505 are the same as those of steps 203 and 212 of FIG.
  • the abnormality detection start output is set at 80% as an example, but the abnormality detection start output can be set to an arbitrary value.
  • the abnormality detection start output may be set to a smaller value in order to notify the disconnection alarm earlier (the abnormality detection start output may be set to "0%"). .. Further, the abnormality detection start output may be set by the user.
  • the dead time and the inclination value at the reference time are acquired based on the self-tuning process, but the present invention is not limited to this.
  • a process for determining the PID constant there is also an auto-tuning process or the like, and based on this, the dead time and the inclination value at the reference time may be acquired.
  • a process for acquiring the dead time and the slope value at the reference time may be performed.
  • the dead time and the inclination value at the reference time may be set in the device in advance (set at the time of shipment from the factory).
  • PID control is described as an example of the control process, but the present invention is not limited to this, and any operation amount for controlling the controlled object is calculated based on the measured value and the target value. It can be used as a control method.
  • the temperature control device has been described as an example of the control device, but the present invention is not limited to the temperature control device, and the present invention is applied to a control device that controls a control target based on an operation amount. Can be done.
  • output of abnormal state information is a process of turning on a warning light
  • the present invention is not limited to this.
  • information may be displayed on a display device, a warning sound may be output, information may be transmitted to an external device, or the like. Further, by logging the abnormal state information to the device, it may be possible to use it for later analysis or the like.
  • the reference change rate (PV change rate) is used and compared as the "reference value determined based on the measured value obtained when a predetermined manipulated variable is input at the reference time”.
  • An example is used in which the rate of change of the measured value is used as the “value based on the measured value”, but the present invention is not limited to this.
  • the "reference value” any value that can evaluate the change in the measured value PV, such as "PV value itself”, can be used. That is, as "a reference value determined based on the measured value obtained when a predetermined manipulated variable is input at the reference time", for example, the PV itself measured at the reference time or a correction coefficient is applied to the PV itself. Values may be used.
  • the "PV measured at the reference time” includes the PV value at a certain point in time (for example, when the dead time elapses or after the dead time elapses for a predetermined time), the average value of the PV values in a certain range, and the PV value in a certain range. It can be appropriately determined based on the design concept of the target device, such as the maximum value and the minimum value of. The same applies to the disconnection reference value. In the above case, in the process of step 206 of FIG. 2, the PV measured at that time is compared with the reference value 1 (which replaces the reference change rate 1).
  • the reference value 1 is a value obtained by multiplying "PV measured at the time of reference” by a coefficient, a value obtained by subtracting a predetermined deviation amount, or the like (stored in the storage unit 12). Further, in the processes of step 203 of FIG. 2 and step 504 of FIG. 5, the PV measured at that time is compared with the disconnection reference value.
  • the disconnection reference value is "PV measured at the time of reference” multiplied by a coefficient, "0", or the like (stored in the storage unit 12). Other processing concepts are the same as those described with reference to FIGS. 2 and 5.

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PCT/JP2020/015334 2020-04-03 2020-04-03 制御装置及び異常検知方法 WO2021199429A1 (ja)

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JP2022511482A JP7266169B2 (ja) 2020-04-03 2020-04-03 制御装置及び異常検知方法
CN202080094099.XA CN115004856B (zh) 2020-04-03 2020-04-03 控制装置及异常检测方法

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