WO2024090159A1 - Data processing system, data collection device, data management device, data processing method, data collection method, and data management method - Google Patents

Abstract

A data processing system according to the present invention comprises: a physical quantity measurement device that measures a physical quantity for each predetermined monitoring cycle; a data collection device that has a collection communication unit which is connected to the physical quantity measurement device and a collection control unit which causes the collection communication unit to provide an external notification of the physical quantity acquired via the collection communication unit; and a data management device that has a management communication unit which is connected to the data collection device, a management control unit which determines that an anomaly has occurred when the physical quantity acquired from the data collection device via the management communication unit has exceeded a predetermined threshold, and a management storage unit which, for each monitoring cycle, stores determination data indicative of the occurrence of the anomaly, wherein when the management storage unit has acquired determination data indicative of the occurrence of an anomaly a predetermined number of times or more consecutively, the management control unit yields a determination result and causes the management communication unit to notify a terminal device of the determination result.

Description

DATA PROCESSING SYSTEM, DATA COLLECTION DEVICE, DATA MANAGEMENT DEVICE, DATA PROCESSING METHOD, DATA COLLECTION METHOD, AND DATA MANAGEMENT METHOD

The present invention relates to a data processing system, a data collection device, a data management device, a data processing method, a data collection method, and a data management method.
This application claims priority to Japanese Patent Application No. 2022-169882, filed in Japan on October 24, 2022, the contents of which are incorporated herein by reference.

　A conventional technology has been disclosed for an abnormality detection device for a pump system that starts and stops multiple pumps that discharge stored water into an outflow pipe depending on the water level in a water storage tank, storing characteristic values of each pump while it is in operation, calculating an average characteristic value per predetermined number of starts from the stored characteristic values, and judging whether or not there is an abnormality in the pumps based on the results of comparing the average characteristic values of each pump (see Patent Document 1).

Japanese Patent Publication No. 2015-034513

Traditionally, a common method of diagnosing a fault is to determine whether the value detected by a sensor is above or below a certain threshold, and to notify an abnormality if the detected value exceeds the threshold.

However, when a sensor detects the state of a device, variations in the sensor's detection value can occur even for devices of the same model, depending on the device's environment or operating method. In other words, depending on the device's installation environment or operating method, it is possible that the sensor may momentarily detect a value that exceeds the threshold even when it is in a normal state. As a result, even if the sensor is in a normal state, the detection value may change due to a temporary change in the environment or operating method, and an abnormality may be reported even when there is no abnormal state. As a result, a large number of sensor abnormality notifications are sent, making it difficult for the user to distinguish between actual abnormality notifications.

In view of the above-mentioned problems, the present invention aims to provide a data processing system, a data collection device, a data management device, a data processing method, a data collection method, and a data management method that can properly notify a user of an abnormality in a sensor.

In order to achieve the above object, a data processing system according to one aspect of the present invention includes a data collection device having a physical quantity measuring device that measures a physical quantity at a predetermined monitoring cycle, a collection and communication unit that connects to the physical quantity measuring device, and a collection control unit that causes the collection and communication unit to notify the physical quantity acquired via the collection and communication unit to an external device, a management and communication unit that connects to the data collection device, a management and control unit that determines that there is an abnormality when the physical quantity acquired from the data collection device via the management and communication unit exceeds a predetermined threshold, and a management and storage unit that stores the abnormality determination data for each monitoring cycle, and the management and control unit determines the result of the determination when the management and storage unit has acquired the abnormality determination data a predetermined number of times or more in succession, and a data management device that causes the management and communication unit to notify the terminal device of the result of the determination.

The data processing system according to the present invention can properly notify the user of sensor abnormalities.

　Problems, configurations and effects other than those mentioned above will be made clear in the detailed description of the invention described below.

1 is an overall configuration diagram showing an example of a data processing system according to an embodiment of the present invention; 1 is a block diagram showing an example of a physical quantity measuring device according to an embodiment of the present invention. FIG. 2 is a block diagram showing an example of a data collection device according to the present embodiment. 13 shows an example of abnormality determination in this embodiment. 4 shows an example of notification items according to the present embodiment. 1 is a block diagram showing an example of a data management device according to an embodiment of the present invention; FIG. 2 is a hardware configuration diagram showing an example of a computer constituting each device of the present embodiment. 4 is a flowchart illustrating an example of a data processing method according to the first embodiment. 10 is a flowchart illustrating an example of a data processing method according to a second embodiment. 13 is a flowchart illustrating an example of a data processing method according to a third embodiment. 5 is a flowchart showing an example of a method for processing a notification item according to the first embodiment; 13 is a flowchart showing an example of a method for processing a notification item according to the second embodiment; 11 shows notification items such as the result of device abnormality determination and device specifications, which are displayed on an email reply screen used in the notification item processing method of the present embodiment. 13 shows a form for changing a notification item displayed on an email reply screen used in the notification item processing method of the present embodiment. 11 shows notification items such as the result of determining an abnormality in a device by an application used in the method for processing notification items of the present embodiment, and the specifications of the device. 11 shows a screen for changing notification items of an application used in the notification processing method of the present embodiment. 11 shows a confirmation screen for changing notification items of an application used in the notification processing method of the present embodiment.

Below, an embodiment for carrying out the present invention will be described with reference to the drawings. Below, the scope necessary for the explanation to achieve the object of the present invention will be shown in a schematic manner, and the scope necessary for the explanation of the relevant parts of the present invention will be mainly described.

(Data Processing System)
1 is an overall configuration diagram showing an example of a data processing system 1 according to the present embodiment. The data processing system 1 functions as a system for processing physical quantity data obtained when a physical quantity of a measurement target is measured by an apparatus and managing the apparatus. The data processing system 1 according to the present embodiment functions as a system for processing physical quantity data obtained when a physical quantity of a measurement target is measured by a pump device 2 and managing the pump device 2.

The data processing system 1 mainly comprises a pump device 2 to be monitored, a physical quantity measuring device 3 that can be attached to the pump device 2, a data collection device 4 configured to be able to communicate with the physical quantity measuring device 3, a data management device 5 configured to be able to communicate with the data collection device 4, and a terminal device 6 configured to be able to communicate with the data management device 5. Each of the devices 2-6 is, for example, configured as a general-purpose or dedicated computer (see FIG. 7 described below), and is configured to be able to mutually send and receive various data via a network 7. The number of each of the devices 2-6 is not limited to the example in FIG. 1, and may be one or more.

The pump device 2 is a device that transports any fluid, and is installed and used in, for example, infrastructure facilities (waterworks, sewage systems, etc.) and plant facilities (oil refineries, power generation, manufacturing, chemical processes, etc.). The pump device 2 includes a pump section 20, a motor 21 that serves as the drive source for the pump device 2, a coupling section 22 that transmits the drive force generated by the motor 21 to the pump section 20, and a pump control panel 23 that controls the operation of the pump device 2.

The pump section 20 is composed of, for example, an impeller, a rotating shaft, bearings, a mechanical seal, a gland packing, a casing, piping, etc. The motor 21 is composed of, for example, an inverter motor or other type of motor. The joint section 22 is composed of, for example, a coupling, joint, bearings, etc. The pump control panel 23 is composed of, for example, an embedded computer. The pump control panel 23 controls the rotation operation of the motor 21 based on the set values of the operating conditions set by a user (the person who installs the pump device 2 or the manager, etc.) and the detection values of sensors (not shown) provided in each part of the pump section 20 and the motor 21. The pump device 2 may be configured to be able to communicate with each of the devices 3 to 6.

The physical quantity measuring device 3 is a device that measures a physical quantity resulting from the pump device 2, and is attached, for example, to any position of the pump section 20, the motor 21, or the joint section 22. The physical quantity measuring device 3 includes a physical quantity sensor 30 that measures the physical quantity of the measurement target, a data processing device 31 that processes physical quantity data obtained when the physical quantity is measured by the physical quantity sensor 30, and a housing 300 that incorporates the physical quantity sensor 30 and the data processing device 31 and can be attached to the pump device 2.

The physical quantity to be measured by the physical quantity sensor 30 is, for example, acceleration (vibration), speed, displacement, environmental sound, etc. The physical quantity sensor 30 is composed of, for example, an acceleration sensor capable of measuring acceleration, a speed sensor capable of measuring speed, a displacement sensor capable of measuring displacement, a microphone capable of measuring environmental sound, etc. Note that the physical quantity to be measured is not limited to the above examples, and may be, for example, pressure, load, temperature, current value, voltage value, etc. In that case, a physical quantity sensor 30 such as a pressure sensor, load sensor, temperature sensor, current sensor, voltage sensor, etc. is used. Furthermore, the physical quantity measuring device 3 may include multiple physical quantity sensors 30 for measuring multiple physical quantities respectively.

The data processing device 31 is a device for processing physical quantity data obtained by converting analog signals indicating physical quantities measured by the physical quantity sensor 30 into digital signals. The data processing device 31 may include an A/D conversion circuit that converts analog signals into digital signals, or may be a device that acquires physical quantity data from the physical quantity sensor 30 after it has been converted into a digital signal.

The mounting position of the housing 300 is determined according to the physical quantity to be measured. Note that one physical quantity measuring device 3 may be attached to the pump device 2, or, as shown in FIG. 1, multiple physical quantity measuring devices 3 may be attached. When multiple physical quantity measuring devices 3 are attached, the multiple physical quantity measuring devices 3 may measure a common physical quantity, or may measure different physical quantities.

The data collection device 4 is a device that collects processed data from the physical quantity measuring device 3 (specifically, the data processing device 31), and is composed of, for example, a repeater such as a gateway, a server, or a portable computer such as a smartphone or tablet. The data collection device 4 collects processed data from the physical quantity measuring device 3 by establishing communication with the physical quantity measuring device 3. In addition, the data collection device 4 has programs such as applications and browsers installed, accepts various input operations, and transmits processed data to the data management device 5. Furthermore, the data collection device 4 can also be interconnected with networks that use different network protocol technologies by converting the protocols.

The data management device 5 includes a management control unit 50 for managing the processing data collected by the data collection device 4, and is configured, for example, as a server-type computer or a cloud-type computer. As described below, the data management device 5 stores the processing data received from the data collection device 4 in the management memory unit 52. In addition, when the processing data received from the data collection device 4 satisfies a predetermined notification condition, the data management device 5 transmits notification information from the management communication unit 51 to the terminal device 6, and transmits reference information in the management memory unit 52 to the terminal device 6 when a reference request for the processing data stored in the management memory unit 52 is received from the terminal device 6.

The terminal device 6 is a device used by a user (such as the manager of the pump device 2 or an inspection/repair worker) located in a remote location away from the installation location of the pump device 2, and is configured, for example, as a stationary computer or a portable computer. Programs such as applications and browsers are installed on the terminal device 6, and the terminal device 6 accepts various input operations and displays various information (notification information and reference information for the management memory unit 52) on the display screen. The terminal device 6 may also be a device that doubles as the data collection device 4.

The network 7 is configured by wired or wireless communication, or a combination of wired and wireless communication, according to any communication standard. Specifically, for example, a standardized communication network such as the Internet, or a communication network managed within a building such as a local network, or a combination of these communication networks can be used. Furthermore, an international standard is typically used as the communication standard for wireless communication. Examples of international standard communication means include IEEE802.15.4, IEEE802.15.1, IEEE802.15.11a, 11b, 11g, 11n, 11ac, 11ad, ISO/IEC14513-3-10, IEEE802.15.4g, etc. Also, methods such as Bluetooth (registered trademark), Bluetooth Low Energy, Wi-Fi, ZigBee (registered trademark), Sub-GHz, EnOcean (registered trademark), and LTE can be used.

(Physical quantity measuring device)
2 is a block diagram showing an example of the physical quantity measuring device 3 of this embodiment. In addition to the above-mentioned physical quantity sensor 30, the physical quantity measuring device 3 includes, as its main components, a measurement control unit 32, a measurement communication unit 33, a measurement storage unit 34, and a power source 35 which constitute a data processing device 31.

The measurement control unit 32 functions as an arithmetic processing unit 320 and a communication processing unit 321, for example, by executing a data processing program 340 stored in the measurement storage unit 34. The measurement communication unit 33 functions as a communication interface that transmits and receives various data to and from, for example, the data collection device 4 via the network 7. The measurement storage unit 34 stores various programs (such as the data processing program 340) and data (such as the measurement setting information 341) used in the operation of the physical quantity measuring device 3. The measurement setting information 341 stores, for example, setting parameters (number of data points, standby time, etc.) referenced by the measurement control unit 32 when the physical quantity measuring device 3 operates, and is configured to be configurable, for example, via the data collection device 4. The power supply 35 is composed of, for example, a primary battery, a secondary battery, a solar cell, a fuel cell, etc., and supplies power to each unit of the physical quantity measuring device 3. The power supply 35 may receive power from the pump device 2.

The calculation processing unit 320 repeatedly acquires the physical quantities of the measurement target measured by the physical quantity sensor 30 as physical quantity data, and generates processed data by performing a predetermined calculation on the acquired physical quantity data. The communication processing unit 321 transmits the processed data generated by the calculation processing unit 320 to the data collection device 4 based on communication from the data collection device 4. The processed data includes the physical quantity data.

When the processing data transmitted by the communication processing unit 321 is received by the data collection device 4, it is further transmitted by the data collection device 4 to the data management device 5, and is stored in the management memory unit 52. Note that, for example, identification information for identifying at least one of the pump device 2 and the physical quantity measuring device 3 (such as the device ID of the pump device 2 or the device ID of the physical quantity measuring device 3) may be added to the processing data by the communication processing unit 321 or the data collection device 4, and in that case, the processing data and the identification information may be stored in the management memory unit 52 in an associated state.

The physical quantity measuring device 3 of this embodiment may be equipped with an anomaly detection function. As an anomaly detection function, for example, a predetermined threshold may be stored in the measurement setting information 341 of the measurement memory unit 34, and the measurement control unit 32 may compare the physical quantity of the physical quantity data with the threshold, and detect the presence of an anomaly if the physical quantity exceeds the threshold. If an anomaly is detected, the measurement communication unit 33 may transmit an anomaly notification to the data collection device 4. The threshold may be set to be compared with the physical quantity in the processing data.

(Data collection device)
3 is a block diagram showing an example of the data collection device 4 according to the present embodiment. The data collection device 4 includes, as its main components, a collection control unit 40, a collection communication unit 41, a collection storage unit 42, a collection input unit 43, and a collection output unit 44.

The collection control unit 40 functions as the collection processing unit 400, for example, by executing the data collection program 420 stored in the collection memory unit 42. The collection communication unit 41 functions as a communication interface that transmits and receives various data between, for example, the physical quantity measuring device 3 and the data management device 5 via the network 7. The collection memory unit 42 stores various programs (such as the data collection program 420) and data types (such as collection setting information 421) used in the operation of the data collection device 4. The collection setting information 421 includes, for example, setting parameters (such as monitoring period) referenced by the collection control unit 40 when the data collection device 4 operates. The collection input unit 43 and the collection output unit 44 function as a user interface by accepting user input operations and outputting various information via a display screen or voice.

The collection processing unit 400 performs a monitoring operation to collect processing data based on a monitoring period. For example, the collection processing unit 400 collects processing data by repeatedly executing a monitoring process in accordance with the monitoring period, which starts communication with the physical quantity measuring device 3, receives processing data from the physical quantity measuring device 3, and ends communication with the physical quantity measuring device 3. The monitoring period is set, for example, in units of seconds, minutes, hours, or days as a value suitable for the monitoring process.

The data collection device 4 of this embodiment may have an anomaly detection function. For example, the anomaly detection function may store a predetermined threshold in the collection setting information 421 of the collection memory unit 42, and the collection control unit 40 may compare the physical quantity in the processing data transmitted from the measurement communication unit 33 with the threshold for each monitoring cycle, and determine that there is an anomaly if the physical quantity exceeds the threshold. Exceeding the threshold may be set to either or both of the cases where the threshold is exceeded and the threshold is exceeded. If the collection control unit 40 determines that there is an anomaly, the collection control unit 40 stores the determination data of the anomaly in the collection memory unit 42 for each monitoring cycle. The collection control unit 40 may determine that there is an anomaly for the physical quantity acquired for each monitoring cycle for a predetermined number of consecutive times or more, and may determine the determination result when the collection memory unit 42 acquires the determination data of the anomaly for a predetermined number of consecutive times or more. The determination result may be "normal", "caution", "warning", etc. The collection control unit 40 may output the judgment result from the collection output unit 44, or notify the terminal device 6 of the judgment result data from the collection communication unit 41 via the data management device 5.

FIG. 4 shows an example of an abnormality determination in this embodiment. In the example shown in FIG. 4, the collection setting information 421 stores a first threshold value and a second threshold value. The collection control unit 40 compares the physical quantity in the processing data transmitted from the measurement and communication unit 33 with the threshold value for each monitoring period. The collection control unit 40 does not determine that there is an abnormality because the physical quantity exceeds the first threshold value at time A, but this is the first time. After that, the collection control unit 40 notifies the determination result of "warning" at time B, when the physical quantity exceeds the first threshold value and the second threshold value twice consecutively. Next, since the collection control unit 40 has already notified the "warning" at time B, it does not notify the determination result of "warning" at time C. Note that if the physical quantity does not exceed the first threshold value or does not exceed the first threshold value a predetermined number of times in a row, the determination result may be "normal".

The data collection device 4 of this embodiment may also notify the notification items together with the determination results stored as data in the collection memory unit 42. For example, the notification items in this embodiment are the items of the target device and the settings of those items. The notification items may be predetermined items or items set in advance by the user. The items and settings may be the specifications of the target device. The notification items are notified to the user's terminal device 6 by email or the like via the data management device 5 and the network 7.

FIG. 5 shows an example of notification items in this embodiment. Notification items are set for each user for each physical quantity sensor 30. The notification items may mainly include the specifications of the device or sensor. In this example, the notification items are the device name, sensor name, sensor installation position, vibration measurement direction, alarm state, notification time, temperature, sound, pressure, etc., but are not limited to these and other notification items may be added. The notification items can be selected by the user and displayed on the screen of the terminal device 6. For example, in the example shown in FIG. 5, user A of the first sensor has selected notification items as device name, sensor name, sensor installation position, vibration measurement direction, alarm state, notification time, and temperature, and non-selected items as sound and pressure. Settings are set for each item. For example, the device name is pump, and the sensor name is vibration, etc. This allows the user to understand that this device is a pump that detects horizontal vibrations of the motor.

The user can change the selected notification items displayed by the terminal device 6, etc. For example, if the user thinks that the temperature is not necessary among the selected notification items, but the volume of the sound included in the non-selected notification items is necessary, the user can change the selected notification item temperature to the non-selected notification item sound, making sound the selected notification item and temperature a non-selected notification item.

The selected notification items can be changed by providing a reply form in the body of the email containing the judgment result sent to the terminal device 6, and having the user change the items. The reply form should allow the user to add a reason for any change made. The selected notification items may also be changed independently of the email containing the judgment result. The data changed by the user is stored in at least one of the data management device 5 and the data collection device 4 via the network 7 from the terminal device 6. The changed data is sent as the selected notification items when notifying the next judgment result. Details of how to change the selected notification items will be described later.

(Data Management Device)
6 is a block diagram showing an example of the data management device 5 according to the present embodiment. The data management device 5 includes, as its main components, a management control unit 50, a management communication unit 51, a management storage unit 52, a management input unit 53, and a management output unit 54.

The management control unit 50 functions as the management processing unit 500, for example, by executing a data management program 520 stored in the management memory unit 52. The management communication unit 51 functions as a communication interface for transmitting and receiving various data to and from, for example, the data collection device 4 via the network 7. The management memory unit 52 stores processing data, various programs (such as the data management program 520) and data types (such as management setting information 521) used in the operation of the data management device 5. The management setting information 521 includes, for example, setting parameters referenced by the management control unit 50 when the data management device 5 operates. The management input unit 53 and management output unit 54 function as a user interface by accepting input operations from the user and outputting various information via a display screen or voice.

The management processing unit 500 performs an operation of downloading the data address and data type, etc. of the physical quantity measuring device 3 registered from the terminal or the management input unit 53, etc., to the data collecting device 4. It also performs an operation of storing the processing data collected by the data collecting device 4 based on the monitoring cycle in the management memory unit 52. For example, when the collection processing unit 400 of the data collecting device 4 starts communication with the management processing unit 500 and transmits the processing data acquired from the physical quantity measuring device 3, the management processing unit 500 executes a management process of storing the processing data in the management memory unit 52. The management process is executed repeatedly according to the monitoring cycle to store the management data.

The data management device 5 of this embodiment may have an anomaly detection function. For example, the anomaly detection function may store a predetermined threshold in the management setting information 521 of the management storage unit 52, and the management control unit 50 may compare a physical quantity in the processing data transmitted from the collection and communication unit 41 with the threshold for each monitoring cycle, and determine that an anomaly exists when the physical quantity exceeds the threshold. Exceeding the threshold may be set to mean either or both of a case where the threshold is exceeded and a case where the threshold is exceeded. When the management control unit 50 determines that an anomaly exists, the management control unit 50 stores determination data indicating that an anomaly exists in the management storage unit 52 for each monitoring cycle.
The management control unit 50 may determine a judgment result when the physical quantity acquired in each monitoring cycle is judged to be abnormal a predetermined number of times or more consecutively, and the management storage unit 52 acquires judgment data indicating abnormality a predetermined number of times or more consecutively. The judgment result may be "normal", "caution", "warning", etc. The management control unit 50 may output the judgment result from the management output unit 54, or notify the terminal device 6 of the judgment result from the management communication unit 51.

In this embodiment, the determination of an abnormality may be performed in the same manner as in the example shown in FIG. 4. The management setting information 521 stores the first threshold and the second threshold. The management control unit 50 compares the physical quantity in the processing data transmitted from the collection and communication unit 41 with the threshold for each monitoring period. The management control unit 50 does not determine that there is an abnormality because the physical quantity exceeds the first threshold at time A, but it is the first time. After that, the management control unit 50 notifies the determination result of "Caution" at time B when the physical quantity exceeds the first threshold two consecutive times. However, although the second threshold is exceeded at time B, it is the first time, so it does not notify the determination result of "Warning". Next, the management control unit 50 notifies the determination result of "Warning" at time C when the physical quantity exceeds the second threshold two consecutive times. Note that if the physical quantity does not exceed the first threshold or does not exceed the first threshold a predetermined number of times in a row, the determination result may be "Normal".

The data management device 5 of this embodiment may also notify the notification items together with the determination results stored as data in the management memory unit 52. For example, the notification items in this embodiment may be the items of the target device and the settings of those items. The items and settings may be the specifications of the target device. The notification items are notified to the user's terminal device 6 by email or the like via the network 7.

The notification items may mainly include the specifications of the device or sensor. In the example shown in FIG. 5, the notification items include the device name, sensor name, sensor installation position, vibration measurement direction, alarm status, notification time, temperature, sound, pressure, etc., but are not limited to these and other notification items may be added. It is not necessary to notify all notification items, and the user can select the notification items. For example, in the example shown in FIG. 5, the selected notification items are the device name, sensor name, sensor installation position, vibration measurement direction, alarm status, notification time, and temperature, and the non-selected notification items are sound and pressure. Each notification item has a setting. For example, the device name is pump, and the sensor name is vibration, etc. This allows the user to understand that this device is a pump that detects horizontal vibrations of the motor.

The user can change the content of the selected notification item using the terminal device 6. For example, as shown in FIG. 5, if the user thinks that the temperature is not necessary among the selected notification items, but the volume of the sound is, the user can change the displayed selected notification item from temperature to sound.

To change the notification items, a reply form can be provided in the body of the email containing the judgment results sent to the terminal device 6, and the user can make the changes. The reply form should allow the user to add a reason for any change they make. The changes made by the user are stored in at least one of the data management device 5 and the data collection device 4 via the network 7 from the terminal device 6. The changed data is sent as the selected notification items when notifying the next judgment results. Details of how to change the notification items will be described later.

The anomaly detection function may be executed by at least one of the physical quantity measuring device 3, the data collecting device 4, and the data management device 5. The anomaly detection function may be executed by two or all of the physical quantity measuring device 3, the data collecting device 4, and the data management device 5 as separate functions. Furthermore, the physical quantity measuring device 3, the data collecting device 4, and the data management device 5 may each have a configuration according to the function of executing the anomaly detection function. For example, when the anomaly detection function is executed by the data management device 5, the physical quantity measuring device 3 and the data collecting device 4 do not need to have a configuration for executing the anomaly detection function.

(Computer)
7 is a hardware configuration diagram showing an example of a computer 900 constituting each device of this embodiment. Each of the pump device 2 (mainly the pump control panel 23), the physical quantity measuring device 3 (mainly the data processing device 31), the data collecting device 4, the data management device 5, and the terminal device 6 is constituted by a general-purpose or dedicated computer 900.

As shown in FIG. 7, the computer 900 includes, as its main components, a bus 910, a processor 912, a memory 914, an input device 916, an output device 917, a display device 918, a storage device 920, a communication I/F (interface) unit 922, an external device I/F unit 924, an I/O (input/output) device I/F unit 926, and a media input/output unit 928. Note that the above components may be omitted as appropriate depending on the application for which the computer 900 is used.

The processor 912 is composed of one or more arithmetic processing devices (CPU (Central Processing Unit), MPU (Micro-Processing Unit), DSP (Digital Signal Processor), GPU (Graphics Processing Unit), NPU (Neural Processing Unit), etc.) and operates as a control unit that controls the entire computer 900. The memory 914 stores various data and programs 930, and is composed of, for example, volatile memory (DRAM, SRAM, etc.) that functions as main memory, non-volatile memory (ROM), flash memory, etc.

The input device 916 is, for example, a keyboard, a mouse, a numeric keypad, an electronic pen, etc., and functions as an input unit. The output device 917 is, for example, a sound (audio) output device, a vibration device, etc., and functions as an output unit. The display device 918 is, for example, a liquid crystal display, an organic EL display, electronic paper, a projector, etc., and functions as an output unit. The input device 916 and the display device 918 may be integrated, such as a touch panel display. The storage device 920 is, for example, a HDD, an SSD, etc., and functions as a memory unit. The storage device 920 stores various data necessary for the execution of the operating system and the program 930.

The communication I/F unit 922 is connected to a network 940 (which may be the same as the network 7 in FIG. 1) such as the Internet or an intranet by wire or wirelessly, and functions as a communication unit that transmits and receives data to and from other computers according to a predetermined communication standard. The external device I/F unit 924 is connected to an external device 950 such as a camera, printer, scanner, or reader/writer by wire or wirelessly, and functions as a communication unit that transmits and receives data to and from the external device 950 according to a predetermined communication standard. The I/O device I/F unit 926 is connected to an I/O device 960 such as various sensors and actuators, and functions as a communication unit that transmits and receives various signals and data, such as detection signals from sensors and control signals to actuators, between the I/O device 960. The media input/output unit 928 is composed of, for example, a drive device such as a DVD drive or a CD drive, a memory card slot, and a USB connector, and reads and writes data to and from media (non-temporary storage media) 970 such as DVDs, CDs, memory cards, and USB memories.

In the computer 900 having the above configuration, the processor 912 calls up the program 930 stored in the storage device 920 into the memory 914, executes it, and controls each part of the computer 900 via the bus 910. The program 930 may be stored in the memory 914 instead of the storage device 920. The program 930 may be recorded on the medium 970 in an installable file format or an executable file format, and provided to the computer 900 via the media input/output unit 928. The program 930 may be provided to the computer 900 by downloading it over the network 940 via the communication I/F unit 922. In addition, the computer 900 may realize various functions that are realized by the processor 912 executing the program 930 using hardware such as an FPGA (Field-Programmable Gate Array) or an ASIC (Application Specific Integrated Circuit).

Computer 900 may be, for example, a desktop computer or a portable computer, and may be any type of electronic device. Computer 900 may be a client computer, a server computer, or a cloud computer, or may be, for example, an embedded computer called a control panel, controller (including a microcomputer, programmable logic controller, or sequencer), etc.

A data processing system including such a physical quantity measuring device 3, data collecting device 4, and data management device 5 can properly notify the user of sensor abnormalities.

(Data Processing Method of the First Embodiment)
FIG. 8 is a flowchart showing an example of a data processing method according to the first embodiment.

The following describes a method in which the data processing system 1 notifies of an abnormality. Here, a physical quantity measuring device 3, a data collecting device 4, a data management device 5, and a terminal device 6 are connected via a network 7 or the like.

First, as shown in FIG. 8, in step S311, it is determined whether the physical quantity measuring device 3 has passed the monitoring period. If in step S311, the physical quantity measuring device 3 has not passed the monitoring period, the process returns to step S311. If in step S311, the physical quantity measuring device 3 has passed the monitoring period, in step S312, the physical quantity measuring device 3 acquires the physical quantity. Next, in step S313, the physical quantity measuring device 3 notifies the data collecting device 4 of the physical quantity.

Next, in step S411, the data collection device 4 acquires the physical quantity from the physical quantity measuring device 3. Then, in step S412, the data collection device 4 notifies the data management device 5 of the physical quantity.

Next, in step S511, the data management device 5 acquires the physical quantity from the data collection device 4. Then, in step S512, the management control unit 50 compares the acquired physical quantity with a predetermined threshold value, and determines that an abnormality exists if the physical quantity exceeds the threshold value.

If, in step S512, the physical quantity does not exceed the threshold and the management control unit 50 determines that there is no abnormality, the process returns to step S311. If, in step S512, the physical quantity exceeds the threshold and the management control unit 50 determines that there is an abnormality, the management control unit 50 stores the determination data indicating that there is an abnormality in the management storage unit 52 in step S513.

Next, in step S514, the management control unit 50 determines whether the management storage unit 52 has continuously acquired data indicating the presence of an abnormality a predetermined number of times or more. If, in step 514, the management control unit 50 has not continuously acquired data indicating the presence of an abnormality a predetermined number of times or more, the process returns to step S311.

If abnormality determination data is obtained consecutively a predetermined number of times or more in step S514, the determination result is determined in step S515. Then, in step S516, the determination result is notified to the user's terminal device 6, etc.

The determination of whether the monitoring period in step S311 has elapsed may be executed by the data collection device 4. The data collection device 4 may notify the physical quantity measuring device 3 that the monitoring period has elapsed, and the physical quantity measuring device 3 may acquire the physical quantity. In addition, the physical quantity acquired in step S512 may be compared with a predetermined threshold value, and if the physical quantity exceeds the threshold value, the determination of whether or not there is an abnormality may be executed by the physical quantity measuring device 3 or the data collection device 4.

(Data Processing Method of the Second Embodiment)
FIG. 9 is a flowchart showing an example of a data processing method according to the second embodiment.

The following describes a method in which the data processing system 1 notifies of an abnormality. Here, a physical quantity measuring device 3, a data collecting device 4, a data management device 5, and a terminal device 6 are connected via a network 7 or the like.

First, as shown in FIG. 9, in step S321, it is determined whether the physical quantity measuring device 3 has passed the monitoring period. If in step S321, the physical quantity measuring device 3 has not passed the monitoring period, the process returns to step S321. If in step S321, the physical quantity measuring device 3 has passed the monitoring period, in step S322, the physical quantity measuring device 3 acquires the physical quantity. Next, in step S323, the physical quantity measuring device 3 notifies the data collecting device 4 of the physical quantity.

Next, in step S421, the data collection device 4 acquires the physical quantity from the physical quantity measuring device 3. Then, in step S422, the collection control unit 40 compares the acquired physical quantity with a predetermined threshold value, and determines that an abnormality exists if the physical quantity exceeds the threshold value.

If, in step S422, the physical quantity does not exceed the threshold and the collection control unit 40 determines that there is no abnormality, the process returns to step S321. If, in step S422, the physical quantity exceeds the threshold and the collection control unit 40 determines that there is an abnormality, the collection control unit 40 stores the determination data indicating that there is an abnormality in the collection storage unit 42 in step S423.

Next, in step S424, the collection control unit 40 determines whether the collection storage unit 42 has continuously acquired data indicating the presence of an abnormality a predetermined number of times or more. If, in step 424, the collection control unit 40 has not continuously acquired data indicating the presence of an abnormality a predetermined number of times or more, the process returns to step S321.

If abnormality determination data is acquired consecutively a predetermined number of times or more in step S424, the determination result is determined in step S425. Then, in step S426, the determination result is notified to the data management device 5.

Next, in step S521, the data management device 5 acquires the determination result from the data collection device 4. Then, in step S522, the data management device 5 notifies the user's terminal device 6 or the like of the determination result.

The determination of whether the monitoring period in step S321 has elapsed may be executed by the data collection device 4. The data collection device 4 may notify the physical quantity measuring device 3 that the monitoring period has elapsed, and the physical quantity measuring device 3 may acquire the physical quantity. Also, the physical quantity measuring device 3 may compare the acquired physical quantity in step S422 with a predetermined threshold value, and determine whether or not there is an abnormality if the physical quantity exceeds the threshold value.

(Data Processing Method of the Third Embodiment)
FIG. 10 is a flowchart showing an example of a data processing method according to the third embodiment.

The following describes a method in which the data processing system 1 notifies of an abnormality. Here, a physical quantity measuring device 3, a data collecting device 4, a data management device 5, and a terminal device 6 are connected via a network 7 or the like.

First, as shown in FIG. 10, in step S331, it is determined whether the physical quantity measuring device 3 has passed the monitoring period. If in step S331, the physical quantity measuring device 3 has not passed the monitoring period, the process returns to step S331. If in step S331, the physical quantity measuring device 3 has passed the monitoring period, in step S332, the physical quantity measuring device 3 acquires a physical quantity.

Next, in step S333, the measurement control unit 32 compares the acquired physical quantity with a predetermined threshold value, and determines that an abnormality exists if the physical quantity exceeds the threshold value.

If, in step S333, the physical quantity does not exceed the threshold and the measurement control unit 32 determines that there is no abnormality, the process returns to step S331. If, in step S333, the physical quantity exceeds the threshold and the measurement control unit 32 determines that there is an abnormality, the process notifies the data collection device 4 of the determination that there is an abnormality in step S334.

Next, in step S431, the data collection device 4 obtains a determination that an abnormality exists from the physical quantity measuring device 3. Then, in step S432, the data collection device 4 notifies the data management device 5 of the determination that an abnormality exists.

Next, in step S531, the data management device 5 obtains a determination of an abnormality from the data collection device 4 and stores it in the management memory unit 52.

Next, in step S532, the management control unit 50 determines whether the management storage unit 52 has continuously acquired data indicating the presence of an abnormality a predetermined number of times or more. If, in step 532, the management control unit 50 has not continuously acquired data indicating the presence of an abnormality a predetermined number of times or more, the process returns to step S331.

If abnormality determination data is obtained consecutively a predetermined number of times or more in step S532, the determination result is determined in step S533. Then, in step S534, the determination result is notified to the user's terminal device 6, etc.

The determination of whether the monitoring period in step S331 has elapsed may be executed by the data collection device 4. The data collection device 4 may notify the physical quantity measuring device 3 that the monitoring period has elapsed, and the physical quantity measuring device 3 may acquire the physical quantity. Also, the data collection device 4 may compare the acquired physical quantity in step S333 with a predetermined threshold value, and determine whether or not there is an abnormality if the physical quantity exceeds the threshold value. Furthermore, steps S531 to S533 may be executed by the data collection device 4.

Such a data collection method, data management method, or data processing method can properly notify the user of sensor abnormalities.

(Method of Processing Notification Items in the First Embodiment)
FIG. 11 is a flowchart showing an example of a method for processing a notification item according to the first embodiment.

The following describes a method for processing notification items executed by the data processing system 1. Here, a physical quantity measuring device 3, a data collecting device 4, a data management device 5, and a terminal device 6 are connected via a network 7 or the like. Note that notification items may be notified together with the judgment result, or may be notified independently of the judgment result.

First, as shown in FIG. 11, in step S541, the data management device 5 notifies the terminal device 6 of notification items such as the current device specifications via the data management communication unit 51.

Next, in step S641, the terminal device 6 acquires the notification items. Then, in step S642, the terminal device 6 changes the notification items. Note that it is not necessary to change the notification items. Next, in step S643, the terminal device 6 notifies the data management device 5 of the changed notification items via the data management communication unit 51. If there are no changes to the notification items, there is no need to notify, or the terminal device 6 may notify the unchanged notification items.

Next, in step S542, the data management device 5 acquires the changed notification items from the terminal device 6. Then, in step S543, the data management device 5 stores the changed notification items in the management storage unit 52. The changed notification items are notified together with the judgment result the next time the judgment result is notified.

(Method of handling notifications)
FIG. 12 is a flowchart showing an example of a method for processing a notification item according to the second embodiment.

The following describes a method for processing notification items executed by the data processing system 1. Here, a physical quantity measuring device 3, a data collecting device 4, a data management device 5, and a terminal device 6 are connected via a network 7 or the like. Note that notification items may be notified together with the judgment result, or may be notified independently of the judgment result.

First, as shown in FIG. 12, in step S451, the data collection device 4 notifies the data management device 5 of notification items such as device specifications via the data collection and communication unit 41.

Next, in step S551, the data management device 5 acquires the notification items from the data collection device 4 via the data management communication unit 51. Then, in step S552, the data management device 5 notifies the terminal device 6 of the notification items together with the determination result of the device abnormality via the data management communication unit 51.

Next, in step S651, the terminal device 6 acquires the notification items. Then, in step S652, the terminal device 6 changes the notification items. Note that it is not necessary to change the notification items. Next, in step S653, the terminal device 6 notifies the data management device 5 of the changed notification items via the data management communication unit 51. If there are no changes to the notification items, no notification is necessary, or the terminal device 6 may notify the unchanged notification items.

Next, in step S553, the data management device 5 acquires the changed notification items from the terminal device 6. Then, in step S554, the data management device 5 notifies the data collection device 4 of the changed notification items via the data management communication unit 51.

Next, in step S554, the data collection device 4 acquires the changed notification items from the data management device 5 via the data collection communication unit 41. The data collection device 4 then stores the changed notification items in the collection storage unit 42. The changed notification items are notified together with the judgment result the next time the judgment result is notified.

(Method of handling notifications using reply emails)
Fig. 13 and Fig. 14 show examples of reply screens used in the notification processing method of this embodiment. Fig. 13 shows notification items such as device anomaly determination results and device specifications, which are shown on the email reply screen used in the notification processing method of this embodiment. Fig. 14 shows a notification item change form shown on the email reply screen used in the notification item processing method of this embodiment.

In the example shown in Figures 13 and 14, the data management device 5 sends an email to the terminal device 6 to inform the user of the results of the device abnormality determination and notification items such as device specifications, and the user can change the notification items in a reply form.

In the example shown in FIG. 13, the body of the email displays the judgment result "Caution" and the notification items. In this example, the notification items include the device name, sensor name, sensor installation position, vibration measurement direction, alarm status, notification time, temperature, etc., which are stored as data in the management memory unit 52.

Below the determination results and notifications shown in Figure 13, a reply form is created in which the user can enter instructions for changing the notification items and the reasons for doing so, as shown in Figure 14. The user checks the notification items to be deleted and the notification items to be added, and enters the reason for changing the notification items. Note that notification items do not have to be deleted or added. In that case, the user does not have to check the items or enter a reason. Multiple notification items may be deleted or added. Furthermore, even if the user changes a notification item, they do not have to enter a reason for the change.

(How to handle notifications using the app)
Fig. 15 to Fig. 17 show examples of the screen of an app used in the method for processing notification items of this embodiment. Fig. 15 shows the result of device abnormality determination by the app used in the method for processing notification items of this embodiment, and notification items such as device specifications. Fig. 16 shows a screen for changing notification items of an app used in the method for processing notification items of this embodiment. Fig. 17 shows a confirmation screen for changing notification items of an app used in the method for processing notification items of this embodiment.

In the example shown in FIG. 15, the application screen displays the judgment result "Caution" and the notification items. In this example, the notification items are the device name, sensor name, sensor installation position, vibration measurement direction, alarm status, notification time, temperature, etc., stored as data in the management memory unit 52. Here, the user decides whether or not to change the notification items. If they do, they select "Yes," and if they do not, they select "No." If "Yes" is selected in FIG. 15, the screen will move to FIG. 16, and if "No" is selected, the screen will end.

The user changes the notification items on the screen shown in FIG. 16. A list of the currently sent notification items is displayed on the left side of the screen shown in FIG. 16. In the example shown in FIG. 16, the user selects the number of the notification item that he or she wants to delete next. The right side of the screen shown in FIG. 16 shows notification items that are not currently selected but can be selected. In the example shown in FIG. 16, the user selects the number of the notification item that he or she wants to add next. The reason for the change is entered in the box at the bottom right of the screen shown in FIG. 16.

The number of the selected notification item is inverted or colored, etc., so that it is clear that it has been selected. In addition to the number, it is sufficient that at least one of the notification items is inverted or colored, etc.

The user selects the notification items to be deleted and the notification items to be added, and enters the reason for changing the notification items. Note that it is not necessary to delete or add notification items. In that case, the user does not need to make a selection or enter a reason. Also, multiple notification items may be deleted or multiple notification items may be added. In that case, the user can simply select multiple items. Furthermore, even if the user selects notification items to be deleted and notification items to be added, it is not necessary to enter a reason for the change.

After selecting the notification items to be deleted and the notification items to be added, the user selects "Next" in the bottom right corner of the screen shown in FIG. 16. Note that even if the user does not select the notification items to be deleted and the notification items to be added, they can simply press "Next."

The user confirms the selected notification item and the reason for the change on the screen shown in FIG. 17. When the user selects "Confirm", data on the selected notification item and the reason for the change is sent to the data management device 5 and stored in the management memory unit 52 of the data management device 5. The user can set the notification items that they want to know about. The administrator can confirm the notification items selected by the user and the reason for the change entered by the user, making improvements to provide more appropriate notifications.

As described above, according to the data processing system 1 of this embodiment, when abnormality determination data is acquired consecutively a predetermined number of times or more, a determination result is determined and notified to the terminal device, so that the user can be appropriately notified of the sensor abnormality.

Furthermore, according to the data processing system 1 of this embodiment, data on notification items including at least one stored device specification is notified to the terminal device along with the judgment result, and data on notification items changed on the terminal device is stored, so that the user can set the notification items he or she wants to know and can appropriately find out the desired information. Furthermore, the administrator can check the notification items selected by the user and the reason for the change entered by the user, making improvements to enable more appropriate notifications.

Other Embodiments
The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit and scope of the present invention. All such modifications are included in the technical concept of the present invention.

In the above embodiment, a case has been described in which the data processing device 31 is realized by the physical quantity measuring device 3, which is a device separate from the pump device 2. Alternatively, some or all of the functions of the data processing device 31 (particularly the functions of the measurement control unit 32) may be realized by the pump device 2 by being incorporated into the pump control panel 23 of the pump device 2. In that case, the physical quantity sensor 30 and the pump control panel 23 may be connected by wire or wirelessly to transmit and receive various data. The pump device 2 may also be provided with the physical quantity sensor 30.

In the above embodiment, a case has been described in which the processed data transmitted by the physical quantity measuring device 3 is relayed by the data collecting device 4, received by the data management device 5, and stored in the management storage unit 52 as a storage device. Alternatively, the device to which the processed data is transmitted and the storage device to which the processed data is stored may be changed as appropriate. For example, the processed data may be transmitted to the data management device 5 or the terminal device 6, or may be stored in a storage device provided in the data collecting device 4 or the terminal device 6.

In the above embodiment, the physical quantity measuring device 3, the data collecting device 4, and the data management device 5 operate according to the flowcharts shown in Figs. 8 to 11. Alternatively, the order in which each step is executed may be changed as appropriate, or some steps may be omitted.

In the above embodiment, the physical quantity measuring device 3 is described as being attached to the pump device 2, but it may also be attached to various devices, such as a refrigerator, a gas machine, a machine tool, a press machine, a conveying machine, a diagnostic machine, etc. In that case, the physical quantity sensor 30 may be configured to measure the physical quantity resulting from the various devices.

The data processing system according to the present invention can properly notify the user of sensor abnormalities.

1...data processing system, 2...pump device, 3...physical quantity measuring device, 4...data collection device, 5...data management device, 6...terminal device, 7...network, 20...pump unit, 21...motor, 22...joint unit, 23...pump control panel, 30...physical quantity sensor, 32...measurement control unit, 33...measurement communication unit, 34...measurement memory unit, 35...power supply, 40...collection control unit, 41...collection communication unit, 42...collection memory unit, 43...collection input unit, 44...collection output unit, 50...management control unit, 51...management communication unit, 52...management memory unit, 53...management input unit, 54...management output unit

Claims (10)

1. a physical quantity measuring device that measures a physical quantity at each predetermined monitoring period;
   a data collection device including a collection and communication unit connected to the physical quantity measuring device, and a collection control unit that causes the collection and communication unit to notify an external device of the physical quantity acquired via the collection and communication unit;
   a management communication unit connected to the data collection device;
   a management control unit that determines that an abnormality exists when the physical quantity acquired from the data collection device via the management communication unit exceeds a predetermined threshold value;
   as well as,
   a management storage unit that stores the abnormality determination data for each monitoring period;
   having
   the management control unit determines a result of the determination when the management storage unit continuously acquires the abnormality determination data a predetermined number of times or more, and notifies the terminal device of the result of the determination from the management communication unit; and
   Equipped with
   Data processing system.
2. a physical quantity measuring device that measures a physical quantity at each predetermined monitoring period;
   a collection and communication unit connected to the physical quantity measuring device;
   a collection control unit that acquires the physical quantity via the collection and communication unit, and determines that an abnormality exists when the acquired physical quantity exceeds a predetermined threshold value;
   as well as,
   a collection and storage unit that stores the abnormality determination data for each monitoring period;
   having
   the collection control unit determines a result of the determination when the collection storage unit continuously acquires the abnormality determination data a predetermined number of times or more, and causes the collection communication unit to notify the result of the determination to an external device; and
   a data management device including a management communication unit connected to the data collection device, and a management control unit that notifies a terminal device of the result of the determination notified from the data collection device via the management communication unit;
   Equipped with
   Data processing system.
3. The physical quantity measuring device further includes a housing that has a built-in physical quantity sensor and is attachable to the pump device;
   The physical quantity sensor includes:
   measuring the physical quantity caused by the pump device to which the physical quantity measuring device is attached;
   3. The data processing system according to claim 1 or 2.
4. The management control unit:
   notifying the terminal device of data on notification items including the specification of at least one device stored in the management storage unit together with the result of the determination from the management communication unit;
   2. The data processing system according to claim 1, wherein data on the notification items changed by the terminal device is acquired from the management communication unit and stored in the management storage unit.
5. a collection control unit that determines that an abnormality exists when a physical quantity acquired from a physical quantity measuring device that measures a physical quantity at a predetermined monitoring period exceeds a predetermined threshold;
   a collection and storage unit that stores the abnormality determination data for each monitoring period;
   having
   the collection control unit, when the collection storage unit has continuously acquired the abnormality determination data a predetermined number of times or more, determines a result of the determination, and causes a collection communication unit connected to the physical quantity measuring device to notify the result of the determination to an external device.
   Data collection equipment.
6. a management control unit that determines that an abnormality exists when a physical quantity acquired from a physical quantity measuring device that measures a physical quantity at a predetermined monitoring period exceeds a predetermined threshold value;
   a management storage unit that stores the abnormality determination data for each monitoring period;
   A management communication unit connected to the management control unit;
   having
   The management control unit determines a result of the judgment when the management memory unit acquires the judgment data indicating the presence of an abnormality a predetermined number of times or more consecutively, and notifies the terminal device of the judgment result via the management communication unit.
7. A data processing method for processing data using a computer, comprising the steps of:
   acquiring a physical quantity at each predetermined monitoring period;
   determining that an abnormality exists when the acquired physical quantity exceeds a predetermined threshold value;
   storing the abnormality determination data for each monitoring period;
   a step of determining a result of the determination when the stored determination data indicating the presence of an abnormality is continuously acquired a predetermined number of times or more, and notifying a terminal device of the result of the determination;
   Equipped with
   Data processing methods.
8. notifying the terminal device of a notification item including the stored specification of at least one device together with the result of the determination;
   storing data of the notification items changed by the terminal device;
   Equipped with
   The data processing method according to claim 7.
9. A data collection method for collecting data using a computer, comprising the steps of:
   acquiring a physical quantity from a physical quantity measuring device that measures the physical quantity at a predetermined monitoring period;
   determining that an abnormality exists when the acquired physical quantity exceeds a predetermined threshold value;
   storing the abnormality determination data for each monitoring period;
   a step of determining a result of the determination when the stored abnormality determination data is continuously acquired a predetermined number of times or more, and notifying an external device of the result of the determination;
   Equipped with
   Data collection methods.
10. A data management method for managing data using a computer, comprising the steps of:
    acquiring a physical quantity measured at each monitoring cycle;
    determining that an abnormality exists when the acquired physical quantity exceeds a predetermined threshold value;
    storing the abnormality determination data for each monitoring period;
    a step of determining a result of the determination when the stored determination data indicating the presence of an abnormality is continuously acquired a predetermined number of times or more, and notifying a terminal device of the result of the determination;
    Equipped with
    Data management methods.

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