HK1184552B - Automatic remote monitoring and diagnosis system - Google Patents

Description

Automatic remote monitoring and diagnosing system

Technical Field

The invention relates to an automatic remote monitoring and diagnosing system.

Background

For example, an electronic control device for plant equipment or equipment such as a plant (hereinafter referred to as "electronic control device or the like") is affected by an installation environment during operation thereof, and a failure or an abnormality may occur. Therefore, it is necessary to investigate the installation environment of the electronic control device and the like. Conventionally, the survey of the installation environment is generally performed at a certain time, for example, before the delivery of the equipment including the electronic control device and the like, when the equipment is installed, when the equipment is periodically checked, when a certain problem suddenly occurs in the electronic control device and the like. The measurement period of various data in this investigation is a short period of at most about several weeks. That is, the measurement of data is sporadic and abnormality monitoring and diagnosis is not continued for a long period of time.

In addition, in the conventional data measurement, first, an operator such as a contractor who takes in the measurement sets measurement devices such as a thermometer, a hygrometer, an accelerometer, a gas concentration meter, a voltmeter, an ammeter, and an electromagnetic wave meter on the site. Then, after the measurement is performed for a certain period of time, the operator goes to the site again to retrieve measurement data. Further, the following series of processes are usually performed: that is, the retrieved measurement data is analyzed, summarized in a report, and submitted to the client. Therefore, the survey of the installation environment has a problem that much labor and cost are required for measuring, collecting, analyzing, and reporting data.

In addition, conventionally, in the above series of processes, data measurement and collection may be performed automatically. However, data-based analysis and reports of analysis results are not automatically generated. Therefore, the operator needs to retrieve the collected data for analysis and report generation, and the work is labor-intensive and costly.

In order to solve this problem, conventionally, a system for diagnosing the life and the degree of deterioration of equipment used in a plant due to corrosion of metal parts by using environmental information is known (for example, see patent document 1). Patent document 1 discloses that, among various measurement data in the installation environment survey, only temperature, humidity, and corrosive gas concentration, that is, so-called environment data, are measured. The environment data obtained by the measurement is input to the diagnosis client. The diagnostic client sends the environmental data to the diagnostic server. The transmission of the environment data is performed via the internet. The diagnostic server refers to the information stored in the diagnostic database, estimates the lifetime and the degree of deterioration of the device based on the environmental data, and provides the estimation result and the coping method to the diagnostic client.

Further, a system is known which monitors the soundness of the environment in a plant electronic control cabinet as a monitoring target (for example, see patent document 2). Patent document 2 discloses a system in which an environment sensor for measuring the installation environment of various devices in a control cabinet and a physical sensor for measuring the physical quantity of various devices in the control cabinet are installed in the control cabinet. The measurement data of these sensors is transmitted to a monitoring device (computer system) outside the control cabinet by wireless communication. The monitoring device is loaded with an algorithm that monitors the soundness of the control cabinet environment based on the correlation between the change in the measurement data and a knowledge database relating to environmental standards stored in advance. When an abnormality occurs, the occurrence location and cause of the abnormality are estimated, and the contents of countermeasures and help are output to a screen of a monitoring device.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2002-062252

Patent document 2: international publication No. 2009/144820

Disclosure of Invention

Technical problem to be solved by the invention

In the system disclosed in patent document 1, only environmental data that indirectly affects the operation of the electronic control device and the like is measured, and physical data such as voltage, current, electromagnetic wave, and static electricity that directly affects the operation of the electronic control device and the like is not measured. Therefore, it is possible to determine the state of the environmental atmosphere in which the device is placed, and indirectly estimate whether or not there is a possibility of abnormality occurring in the electronic control apparatus or the like from the state of the environmental atmosphere. However, it is not possible to directly determine that an abnormality has occurred in the electronic control device or the like, and to ascertain the cause of the abnormality occurring in the electronic control device or the like, and therefore there is a problem in that an accurate countermeasure for solving the problem cannot be proposed.

Further, in the disclosure of patent document 2, measurement data from the sensor group is transmitted to the monitoring apparatus by wireless communication. Here, in wireless communication, the communicable distance, the number of connections, and the like are limited. Therefore, when the scale of a plant, a factory, or the like to be monitored is large, or when a plurality of remote locations are to be monitored, all the monitoring targets cannot be monitored by only one monitoring apparatus. Therefore, when a plurality of monitoring apparatuses are used according to the scale of the monitoring target or the like, there are problems that the efficiency is low because data cannot be collectively managed, and that the measurement data cannot be referred to from a place other than the monitoring apparatus in which the measurement data is stored.

On the other hand, the disclosure of patent document 1 presupposes that the diagnosis result data of a plurality of monitoring targets are shared among a plurality of diagnosis clients. Therefore, the following structure is provided: that is, the diagnosis client and the diagnosis server are connected via the internet, and the measurement data must be transmitted via the internet. Therefore, there are problems as follows: that is, when the measurement client does not wish to disclose measurement data to another person, or when strict security is required, a system that is closed inside the company or the like cannot be established.

That is, the systems disclosed in patent documents 1 and 2 have a problem that a monitoring and diagnosis system cannot be flexibly constructed according to the status, state, and the like of a monitoring target and a diagnosis requester.

In order to solve the above problems, the present invention has been made to provide an automatic remote monitoring and diagnosing system which can continuously perform automatic measurement and automatic collection of environmental data and physical data related to an electronic control device or the like, analyze the collected data in real time to diagnose whether or not there is an abnormality in the electronic control device or the like, automatically extract the analysis and diagnosis result, automatically extract a processing method as necessary, and flexibly construct the system according to the situation, state, and the like of a monitoring target and a diagnosis requester.

Technical scheme for solving technical problem

The automatic remote monitoring and diagnosis system according to the present invention includes: an environment sensor that measures environment data relating to an installation environment of the electronic control device or the equipment at a predetermined measurement cycle and transmits the measured data by wireless communication; a physical sensor that measures physical data relating to the electronic control device or the equipment at a predetermined measurement cycle and transmits the measured data by wireless communication; a wireless server that collects measurement data transmitted from the environmental sensor and the physical sensor by wireless communication and transmits the collected measurement data at predetermined time intervals; a diagnostic client communicably connected to the wireless server via a first communication network, collecting the measurement data transmitted from the wireless server via the first communication network, and transmitting the collected measurement data at predetermined time intervals; a diagnostic server communicably connected to the diagnostic client via a second communication network, receiving the measurement data transmitted from the diagnostic client via the second communication network, and performing diagnosis of the electronic control apparatus or the device based on the received measurement data; a data storage device that stores the measurement data received by the diagnosis server; and a knowledge database that stores information required for the diagnosis server to perform the diagnosis, the diagnosis server transmitting a result of the diagnosis to the diagnosis client via the second communication network, and when the result of the diagnosis is that there is a problem in the electronic control apparatus or the device, determining a coping method for the problem, and transmitting the coping method to the diagnosis client via the second communication network.

Effects of the invention

The automatic remote monitoring and diagnosis system according to the present invention can automatically measure and collect environmental data and physical data related to an electronic control device and the like continuously, analyze the collected data in real time, diagnose whether or not there is an abnormality in the electronic control device and the like, automatically present the analysis and diagnosis results and, if necessary, a processing method, and can be flexibly constructed according to the status, state, and the like of a monitoring target and a diagnosis requester.

Drawings

Fig. 1 is a diagram illustrating an overall configuration of an automatic remote monitoring and diagnosis system according to embodiment 1 of the present invention.

Fig. 2 is a diagram illustrating an overall configuration of an automatic remote monitoring and diagnosis system according to embodiment 2 of the present invention.

Fig. 3 is a diagram illustrating an overall configuration of an automatic remote monitoring and diagnosis system according to embodiment 3 and embodiment 4 of the present invention.

Fig. 4 is a diagram illustrating an overall configuration of an automatic remote monitoring and diagnosis system according to embodiment 6 of the present invention.

Fig. 5 is a diagram illustrating another overall configuration of an automatic remote monitoring and diagnosis system according to embodiment 6 of the present invention.

Detailed Description

The invention is explained below with reference to the drawings. In the drawings, the same reference numerals denote the same or corresponding parts, and repetitive description thereof will be appropriately simplified or omitted.

Embodiment 1.

Fig. 1 is a diagram according to embodiment 1 of the present invention. Fig. 1 is a diagram showing an overall configuration of an automatic remote monitoring and diagnosis system. In the figure, reference numerals 1a, 1B, and 1C denote a diagnosis principal of the electronic control device and the like, i.e., company a, B, and C, respectively. Although the number of diagnosis clients is 3 here, other numbers are possible. The company a 1a, the company B1B, and the company C1C have electronic control devices (not shown) as objects of monitoring and diagnosis by the automatic remote monitoring and diagnosis system according to the present invention. An environmental sensor 2 and a physical sensor 3 are provided in the housing of the diagnosis client, the electronic control device, and the like, and around the electronic control device, and the like.

The environmental sensor 2 is a sensor group including a plurality of sensors for measuring environmental data such as temperature, humidity, vibration (acceleration), and concentration of corrosive gas. The environmental sensor 2 formed by such a sensor group has the following functions: that is, each measurement element is measured at a predetermined measurement period determined for each measurement element, and the measured data is transmitted by wireless communication.

The temperature, humidity, and corrosive gas in the measurement elements relating to the environmental data, which is the measurement object of the environmental sensor 2, do not change drastically in a short time. Therefore, the measurement cycle of these elements may be set to about 1 minute, 10 minutes, or 30 minutes, for example. On the other hand, it is sufficient to consider that the vibration (acceleration) instantaneously changes. Therefore, it is necessary to perform measurement at short time intervals, and it is preferable to set the measurement period to about 10 milliseconds from the experience of the present inventors.

The configuration of the sensor constituting the environmental sensor 2 will be described in detail below. As the sensor unit for measuring the temperature, humidity, and vibration (acceleration) among the measurement elements related to the environmental data mentioned above, a semiconductor integrated type sensor unit can be used. The semiconductor integrated sensor unit is generally widely used and is easily available. In addition, by incorporating a wireless communication device, an MPU (microprocessing unit), and a memory, which will be described later, into the sensor unit, a small sensor that can be installed inside an electronic control device or the like can be easily configured.

Further, a gas sensor that outputs a measurement result as an electrical signal such as a voltage or a current with respect to the concentration of the corrosive gas is used in the sensor portion, and a sensor that can read the electrical signal has the same configuration as the sensor that measures temperature and humidity described above, whereby a small sensor can be easily realized. The gas sensor that outputs the measurement result as an electrical signal such as voltage or current is, for example, of a semiconductor type, a solid electrolyte type, an electrochemical type, or the like, and any of these types can be used.

The physical sensor 3 is a sensor group including a plurality of sensors for measuring physical data such as voltage, current, electromagnetic wave, and static electricity. The physical sensor 3 constituted by such a sensor group also has the following functions, as with the environmental sensor 2: that is, each measurement element is measured at a predetermined measurement cycle determined for each measurement element, and the measured data is transmitted by wireless communication at predetermined time intervals.

The voltage and current of the measurement element relating to the physical data, which is the object of measurement by the physical sensor 3, change at very short time intervals. For example, it is empirically known that when static electricity is applied, a large change in voltage and current is observed. In order to capture such a change in voltage and current, it is necessary to perform measurement at intervals of at least 10 nanoseconds. On the other hand, there is a demand for measuring the variation of the control power supply voltage and the variation of the consumption current at a stable time in an electronic control device or the like at relatively long time intervals of approximately 10 milliseconds or so.

Therefore, in order to satisfy both of the above requirements, two types of sensors, i.e., a sensor having a long measurement cycle of about 10 milliseconds and a sensor having a very short measurement cycle of about 10 nanoseconds, may be provided as the sensors for measuring the voltage and the current. In contrast, it is empirically determined that electromagnetic waves and static electricity change at a very fast frequency. Therefore, the measurement cycle for these elements is preferably set to about 10 nanoseconds.

The structure of the sensor constituting the physical sensor 3 will be described in detail below. As for measurement elements related to the aforementioned physical data, a sensor unit called a probe for measuring these elements is widely available on the market in general. These probes output measurement results of the respective measurement elements as electrical signals. Therefore, by incorporating a part for receiving an electric signal output from the probe, a wireless communication device, an mpu (microprocessing unit), and a memory, which will be described in detail later, into the probe, a small sensor that can be provided inside an electronic control device or the like can be easily configured.

The diagnostic clients (company a 1a, company B1B, and company C1C) each have a wireless server 4 for collecting measurement data transmitted from the environmental sensors 2 and the physical sensors 3 by wireless communication. The wireless server 4 is disposed at a position within approximately 10 meters of the environmental sensor 2 and the physical sensor 3. The plurality of wireless servers 4 are installed as needed according to the number of installation locations, installation places, and the like of the environmental sensors 2 and the physical sensors 3.

As a wireless communication method between the environmental sensor 2 and the physical sensor 3 and the wireless server 4, for example, a specific energy saving wireless method, a standardized method such as IEEE802.15, or the like is used. As for the wireless communication standard mentioned here, an infrastructure such as a small-sized communication module is generally available on the market. Therefore, each of the sensors used in the environmental sensor 2 and the physical sensor 3 can be miniaturized, and high communication quality can be realized without developing a new technology.

Each diagnosis client (a company 1a, B company 1B, and C company 1C) has a first LAN5a as an intra-company communication network. The first LAN5a is connected to the wireless server 4. The wireless server 4 has a function of transmitting measurement data collected from the environmental sensor 2 and the physical sensor 3 to the first LAN5a at predetermined time intervals.

Each diagnosis client 6 is provided in each diagnosis client (a company 1a, B company 1B, and C company 1C). The diagnosis client 6 is connected to the first LAN5a of each diagnosis principal. The measurement data transmitted from the one or more wireless servers 4 via the first LAN5a is collected.

Each diagnosis client (1a, 1b, 1c) is communicably connected to a maintenance company 8 via the internet 7. The maintenance company 8 is a diagnosis executor that monitors and diagnoses electronic control devices and the like of each diagnosis requester. From the viewpoint of each diagnosis client, the diagnosis client 6 of each diagnosis client (1a, 1b, 1c) is also connected to the internet 7, which is an external network. The maintenance company 8 is provided with a diagnosis server 9, and the diagnosis server 9 is also connected to the internet 7.

The diagnostic client 6 of each diagnostic client (1a, 1b, 1c) transmits the collected measurement data to the diagnostic server 9 of the maintenance company 8 via the internet 7 at predetermined time intervals. The diagnostic server 9 receives measurement data of the environmental sensor 2 and the physical sensor 3 transmitted from the diagnostic client 6 via the internet 7.

The diagnosis server 9 that has received the measurement data stores the received measurement data in the data storage device 10, and analyzes the received measurement data to diagnose the subject. Further, a report of the diagnosis result is generated, and if there is a problem, a method of coping with the problem is determined. The diagnostic server 9 transmits the diagnostic result report and the coping method to the diagnostic client 6 via the internet 7 at a predetermined time interval or each time a request is received from the diagnostic client 6.

The maintenance company 8 is provided with a knowledge database 11 communicably connected to the diagnosis server 9 by a second LAN5b installed in the maintenance company 8. The knowledge database 11 stores inference engines, diagnostic algorithms, and failure-related data required for the diagnostic server 9 to analyze and diagnose objects. The analysis and diagnosis performed by the diagnosis server 9 based on the measurement data of the environmental sensor 2 and the physical sensor 3 are performed with reference to the contents of the knowledge database 11. In addition, the diagnosis server 9 updates the content of the knowledge database 11 as necessary.

The diagnosis of the diagnosis database 9 is performed in the following manner. The diagnostic server 9 sets a threshold value in advance for each measurement element of the environmental sensor 2 and the physical sensor 3. Then, the measured data is compared with the threshold value to determine whether or not the data is abnormal. Further, the degree of environmental pollution and the degree of metal corrosion are estimated based on the temperature, humidity, and corrosive gas concentration measured by the environmental sensor 2 by a known method such as that described in patent document 1, for example, and the life of the metal part is predicted. Further, deterioration diagnosis of the electronic control apparatus and the like is performed using the inference engine, the diagnostic algorithm, and the failure-related data in the knowledge database 11, and the environmental data and the physical data measured by the environmental sensor 2 and the physical sensor 3. The inference engine and the diagnosis algorithm may be constituted by such a known manner as described in patent document 2, for example. That is, independent logical groups, independent inference engines, direct execution of algorithms, etc. may be used, regardless of implementation.

The first LAN5a of each diagnosis client (1a, 1b, 1c), the second LAN5b of the maintenance company 8, and the internet 7 can be constructed by a general technique.

In the automatic remote monitoring and diagnosis system according to the present invention, environmental measurement and environmental diagnosis are performed as follows.

First, the environmental sensor 2 and the physical sensor 3 are installed in the target electronic control device, and the wireless server 4 and the diagnostic client 6 are installed according to the size of the target. The maintenance company 8 is provided with a diagnosis server 9 and a knowledge database 11, and connects the diagnosis client 6 and the diagnosis server 9 via the internet 7. After the installation of each device constituting the system is completed, the switches of the environmental sensor 2 and the physical sensor 3 are turned on.

Then, the environment sensor 2 and the physical sensor 3 measure the respective measurement elements at the predetermined measurement cycle, and transmit the measured data to the wireless server 4 at predetermined time intervals by wireless communication. The wireless server 4 collects the measurement data transmitted from the environmental sensors 2 and the physical sensors 3, and transmits the collected measurement data to the diagnostic client 6 via the first LAN5a at predetermined time intervals. The diagnostic client 6 collects measurement data transmitted from the wireless server 4 via the first LAN5a, and transmits the collected measurement data to the diagnostic server 9 of the maintenance company 8 via the internet 7 at predetermined time intervals.

The diagnosis server 9 receives measurement data transmitted from the diagnosis client 6 via the internet 7, and stores the measurement data in the data storage device 10. The electronic control devices and the like of the diagnosis clients (company a 1a, company B1B, and company C1C) are diagnosed by referring to the knowledge database 11 based on the received measurement data of the environmental sensor 2 and the physical sensor 3. The diagnostic server 9 generates a report of the diagnostic result, and determines a method of handling the diagnostic result when the diagnostic result indicates that a problem is found.

The diagnostic server 9 transmits the diagnostic result report and the coping method to the diagnostic client 6 via the internet 7 at a predetermined time interval or each time a request is received from the diagnostic client 6. The diagnosis client 6 includes an output device such as a display or a printer, and the diagnosis client 6 presents a diagnosis result report and a coping method transmitted from the diagnosis server 9 via the internet 7 to the user via the output device.

In such an automatic remote monitoring and diagnosis system, installation and setting of various devices such as sensors, servers, and clients are performed by an operator as usual. However, once the setting is once completed and the measurement is started, the series of subsequent data measurement, measurement data input, storage, diagnosis, analysis, report generation, and handling method determination can be automatically performed without human intervention. Further, since the diagnostic result report and the measurement data are generated and stored as electronic data, it is helpful to reduce labor and cost, which are problems in the conventional environmental diagnosis. In addition, since all of them are carried out in an automatic manner, diagnosis can be carried out in real time.

In addition, in the automatic remote monitoring and diagnosis system, measurement, data transmission, and diagnosis are continuously performed, and a continuous monitoring state is realized. Therefore, even for various problems that occur suddenly or sporadically in an electronic control device or the like that is a monitoring target, a coping method has been proposed that can store and analyze measurement data when such a problem occurs, and can specify a cause. Further, since automatic measurement and automatic diagnosis can be performed for a long period of time, for example, 5 years or 10 years, there is an advantage that not only a problem instantaneously occurring in an electronic control device or the like but also an environmental factor that affects the electronic control device over a medium-long period can be identified.

The above automatic remote monitoring diagnosis system has functions provided to the user in the following manner. That is, the present system is configured using IT technology such as wireless communication, the internet, and a server-client system. Therefore, various services using such IT technology can be provided. For example, the protection and maintenance services that the automatic remote monitoring and diagnosis system according to the present application can provide to the user can be considered as the following services. The user, i.e., the diagnosis client, selects a service required by the user from the following services, and pays a reward to the diagnosis executor, thereby establishing a service.

Storage of environmental data

Implementation of environmental diagnostics and Generation of environmental diagnostics reports

Proposing a coping method based on environmental diagnosis report

Identification of causes when sudden or sporadic problems occur, and proposal of a method for dealing with the problems

Implementation of degradation diagnosis and Generation of degradation diagnosis report

Proposing a coping method based on a deterioration diagnosis report

Provision of maintenance measures

Further, the devices such as the sensors, the client, and the server constituting the automatic remote monitoring and diagnosis system may be installed in advance when the electronic control device and the like are shipped from a factory, or may be installed in the electronic control device and the like that are already in operation.

The automatic remote monitoring diagnosis system having the above structure includes: an environment sensor that measures environment data relating to an installation environment of the electronic control device or the like at a predetermined measurement cycle and transmits the measured data by wireless communication; a physical sensor that measures physical data relating to an electronic control device or the like at a predetermined measurement cycle and transmits the measured data by wireless communication; a wireless server that collects measurement data transmitted from the environmental sensor and the physical sensor by wireless communication and transmits the collected measurement data at predetermined time intervals; a diagnostic client communicably connected to the wireless server via a first LAN, which is a first communication network, and configured to collect measurement data transmitted from the wireless server via the first LAN and to transmit the collected measurement data at predetermined time intervals; a diagnostic server communicably connected to the diagnostic client via the internet serving as a second communication network, receiving the measurement data transmitted from the diagnostic client via the internet, and performing diagnosis of the electronic control apparatus and the like based on the received measurement data; a data storage device that stores the measurement data received by the diagnosis server; and a knowledge database storing information required by the diagnosis server when performing diagnosis; the diagnostic server transmits the diagnostic result to the diagnostic client via the second communication network, determines a coping process for a problem in the electronic control device or the like when the diagnostic result indicates the problem, and transmits the coping process to the diagnostic client via the second communication network.

Therefore, it is possible to continuously perform automatic measurement and automatic collection of environmental data and physical data relating to an electronic control device or the like, analyze the collected data in real time to diagnose whether or not there is an abnormality in the electronic control device or the like, automatically present the analysis and diagnosis result, automatically present a processing method as necessary, and flexibly construct the data according to the situation, state, and the like of a monitoring target and a diagnosis requester.

Embodiment 2.

Fig. 2 is a diagram according to embodiment 2 of the present invention, and is a diagram illustrating an overall configuration of an automatic remote monitoring and diagnosing system.

Embodiment 2 described here focuses particularly on storage and provision of the measured environmental data in embodiment 1.

That is, in the automatic remote monitoring and diagnosis system according to the present invention, as shown in fig. 2, the diagnosis client 6 and the diagnosis server 9 are communicably connected via the internet 7 as described in the foregoing embodiment 1. Therefore, the measurement data can be continuously transmitted from the diagnosis client 6 to the diagnosis server 9 at predetermined time intervals. Therefore, the measurement data from the start of measurement to the present can be continuously stored in the data storage device 10 on the diagnosis server 9 side.

The a company 1a, which is a measurement/diagnosis requester, operates the diagnosis client 6 of the a company 1a, and transmits a request specifying an item and a period of necessary environment data to the diagnosis server 9. The diagnostic server 9 that has received the request takes out the specified data from the data storage device 10 based on the content of the request, and transmits the data to the diagnostic client 6 that has issued the request via the internet 7. The diagnostic client 6 also displays the environment data transmitted from the diagnostic server 9 to the user using an output device.

In addition, since the internet 7 is used for communication between the diagnostic client 6 and the diagnostic server 9, confidentiality and security of communication contents also need to be considered. Therefore, authentication using an ID and a password or encryption using an encryption technique such as SSL can be performed in communication between the diagnostic client 6 and the diagnostic server 9.

The diagnostic server 9 may have a function of collecting data for each arbitrary predetermined period, such as a daily report, a monthly report, and an annual report, and may have a function of outputting the collected data as an electronic file.

Other structures are the same as those of embodiment 1, and detailed description thereof is omitted.

In the automatic remote monitoring and diagnosing system having the above structure, the following effects are provided: that is, the diagnosis client does not need to perform not only the measurement, which requires labor, but also the data storage. Further, the following effects are also provided: that is, the diagnostic client can obtain environment measurement data for an arbitrary period when necessary by operating the diagnostic client. The diagnostic server has a function of collecting data for each arbitrary predetermined period such as a daily report, a monthly report, and a yearbook report, and can provide maintenance data to the diagnostic client by outputting the collected data as an electronic file. And thus has the following effects: that is, the environmental diagnosis client can easily manage the measurement work and the measurement data, and is free from the troublesome storage.

Embodiment 3.

Fig. 3 is a diagram according to embodiment 3 of the present invention, and is a diagram illustrating an overall configuration of an automatic remote monitoring and diagnosing system.

Embodiment 3 described here focuses particularly on the implementation of environmental diagnosis and the generation of an environmental diagnosis report, the proposal of a coping process based on an environmental diagnosis report, and the identification of a cause when a sudden or sporadic problem occurs and the proposal of a coping process against the problem in embodiment 1 described above.

That is, in the automatic remote monitoring and diagnosis system according to the present invention, as described in embodiment 1 above, the diagnosis server 9 can perform environmental diagnosis on the electronic control device or the like owned by the diagnosis requester based on the measurement data transmitted from the diagnosis client 6 via the internet 7. In the environmental diagnosis, the threshold set in the diagnosis server 9, the inference engine installed in the knowledge database 11, and the like are used.

Here, as also described in embodiment 2, the measurement data from the start of measurement to the present is continuously stored in the diagnostic server 9. Therefore, by using the stored data, it is possible to perform environmental diagnosis of the electronic control device and the like at an arbitrary timing and in an arbitrary period, and to generate an environmental diagnosis report by aggregating the results into a predetermined report format. In this case, the period and time for performing the environment diagnosis may be negotiated between the a company 1a, which is the diagnosis requester, and the maintenance company 8, which is the diagnosis executor.

Alternatively, the diagnosis client 6 may be operated by the diagnosis principal (a corporation 1a) to request the environment diagnosis from the diagnosis server 9 at any time. The diagnostic server 9 that has received the environmental diagnosis request performs environmental diagnosis using the measurement data stored in the data storage device 10, and generates an environmental diagnosis report based on the result. The diagnostic server 9 transmits the environmental diagnostic report to the diagnostic client 6 via the internet 7. The diagnostic client 6 also displays the environmental diagnostic report transmitted from the diagnostic server 9 to the user using an output device.

As described in embodiment 1 above, the diagnostic server 9 can detect a failure in an electronic control device or the like owned by a diagnostic client based on measurement data transmitted from the diagnostic client 6 via the internet 7. Then, the cause of the failure can be estimated or identified, and a coping method for the failure can be determined. The threshold set in the diagnosis server 9 and the data related to the failure installed in the knowledge database 11 are used for the detection of the failure and the estimation of the cause thereof.

Further, a method of handling when a problem such as a failure of a monitoring target is found can be presented to the diagnosis client (company a 1a) via the internet 7 at once. In the case where the service agreement between the client and the implementor has not been previously signed up until the method of coping is proposed, the diagnosis client 6 can be operated by the diagnosis client to request the method of coping at any time.

As described above in embodiment 1, the diagnostic server 9 acquires measurement data of the environmental sensor 2 and the physical sensor 3 in the electronic control device of the diagnosis requester or the like in real time. Therefore, in the case where a problem occurs suddenly or sporadically in an electronic control device or the like, the cause can be identified by performing data analysis at the time of occurrence of the problem immediately, and the cause can be presented to the diagnosis client 6 of the diagnosis principal via the internet 7.

Further, for a principal who has not previously signed a service agreement with an implementer for identifying and proposing a coping method for the cause of such sudden or sporadic problems, the diagnosis principal may also operate the diagnosis client 6 so as to request the provision of such a service at an arbitrary timing. In this case, the diagnostic server 9 may store the environmental diagnosis result, the cause specification result, and the coping method in the data storage device 10 or the like.

In this embodiment, the above-described service request from the client side and service provision from the implementer side may be performed by the financial institution 12 connected to the internet 7. This makes it possible to secure secrecy and security of information by using an online credit card authentication service or the like provided in the financial institution 12. Also, payment of the reward can be automatically settled by account transfer or the like in the financial institution 12 later.

Other structures are the same as those of embodiment 1, and detailed description thereof is omitted.

In the automatic remote monitoring and diagnosis system having the above configuration, the diagnosis requester can obtain the environmental diagnosis result in real time as needed. Further, the coping process of the present apparatus can be obtained in real time, and the coping process can be obtained immediately when a problem occurs.

Embodiment 4.

Embodiment 4 described here focuses particularly on implementation of the deterioration diagnosis, generation of a deterioration diagnosis report, and presentation of a coping method based on the deterioration diagnosis report in embodiment 1 described above. The configuration of the automatic remote monitoring and diagnosis system according to the present embodiment is the same as that of embodiment 3 except for the following description, and therefore, the description is given with reference to fig. 3.

That is, in the automatic remote monitoring and diagnosis system according to the present invention, as described above in embodiment 2, the measurement data from the start of measurement to the present is continuously stored in the data storage device 10. Therefore, the change in the measurement data in time series can be easily observed. Further, by observing the time-series change of the measurement data, it is possible to perform deterioration diagnosis on the electronic control device or the like as the monitoring target. Further, the result of the deterioration diagnosis is compiled into a predetermined report format, whereby a deterioration diagnosis report can be generated. Specifically, for example, deterioration of the control power supply can be determined by checking the time-series change of the spike noise based on the voltage measurement data among the measurement data of the physical sensor 3.

Further, the diagnosis client 6 may also be operated by a diagnosis principal (a corporation 1a) to enable a request for a deterioration diagnosis to the diagnosis server 9 at an arbitrary timing. The diagnosis server 9 that has received the degradation diagnosis request performs degradation diagnosis using the measurement data stored in the data storage device 10, and generates a degradation diagnosis report based on the result. The diagnosis server 9 transmits the deterioration diagnosis report to the diagnosis client 6 via the internet 7. Also, the diagnosis client 6 displays the deterioration diagnosis report transmitted from the diagnosis server 9 to the user using an output device.

Further, based on the deterioration diagnosis of the electronic control device and the like by the diagnosis server 9, a method of coping with the problem finding can be immediately proposed to the diagnosis client through the internet 7. In the case where the service agreement between the client and the implementor has not been previously signed up until the method of coping is proposed, the diagnosis client 6 can be operated by the diagnosis client to request the method of coping at any time.

In this embodiment, as in embodiment 3, the request for degradation diagnosis and the transmission of the degradation diagnosis result may be performed by the financial institution 12 connected to the internet 7. This makes it possible to secure secrecy and security of information by using an online credit card authentication service or the like provided in the financial institution 12. Also, payment of the consideration can be automatically settled by account transfer in the financial institution 12 later.

With the above configuration, the environmental diagnosis result and the deterioration diagnosis result can be stored in the data storage device 10 of the diagnosis server 9 for each device of the diagnosis requester. Further, based on these data, the content of implementation when the equipment is periodically checked, that is, the equipment check consultation is determined. Specifically, for example, if it is found that the control power supply is deteriorated, it is possible to propose a replacement of the power supply. Further, if the noise amount of the AC power supply is found to increase, it is possible to propose a filter to be added, and if the humidity tends to decrease, it is possible to propose a humidifier to be provided.

In the automatic remote monitoring and diagnosis system having the above configuration, the diagnosis requester can obtain the deterioration diagnosis result in real time as needed. In addition, the diagnosis client can obtain a coping method in real time when the apparatus is deteriorated. Also, improvement in the life of the electronic control device and the like is also helped.

Embodiment 5.

Embodiment 5 described here can detect an abnormality in the device on the diagnosis requester side constituting the present system, such as the sensor, the wireless server, and the diagnosis client, in embodiment 1 described above.

That is, in the automatic remote monitoring and diagnosis system according to the present application, as described in embodiment 2 above, measurement data is continuously transmitted from the diagnosis client 6 to the diagnosis server 9 at predetermined time intervals. Therefore, the diagnostic server 9 monitors whether or not the measurement data is missing, and when the absence of the measurement data from the diagnostic client 6 is detected, it can be determined from the diagnostic client 6 of the diagnosis requester that some abnormality has occurred in the device on the diagnostic side, specifically, the environmental sensor 2, the physical sensor 3, the wireless server 4, the first LAN5a, the diagnostic client 6, or the like.

In the case where the value of the transmitted data cannot be used as the measurement value, the diagnosis server 9 can determine that the value is abnormal in the environmental sensor 2 or the physical sensor 3 by using the knowledge database 11. When the abnormality is detected, the diagnostic server 9 may transmit a signal of the abnormality to the diagnostic client 6 via the internet 7 and issue a warning to the diagnostic client 6 that has received the signal.

The wireless server 4 and the diagnosis client 6 on the diagnosis requester side may have such an abnormality detection function, not only the diagnosis server 9. That is, the environment sensor 2 and the physical sensor 3 and the wireless server 4, and the wireless server 4 and the diagnostic client 6 continuously communicate measurement data at regular time intervals. Therefore, in the case where the communication with the respective communication destinations is interrupted in the wireless server 4 and the diagnostic client 6, it is possible to detect that an abnormality such as a failure has occurred in the device on the communication destination side. For example, in the case where an abnormality is detected by the diagnostic client 6, it is possible to detect an abnormality of the environmental sensor 2, the physical sensor 3, the wireless server 4, or the like.

In this case, the wireless server 4 and the diagnosis client 6 that have detected an abnormality in the device to be communicated may issue a warning of the abnormality on the spot, or may notify the former device of the abnormality (the wireless server 4 notifies the diagnosis client 6 and the diagnosis server 9, and the diagnosis client 6 notifies the diagnosis server 9).

In the automatic remote monitoring and diagnosis system having the above configuration, the diagnosis executor can provide the environment diagnosis requester with a measurement system having very high reliability.

Embodiment 6.

Fig. 4 and 5 are diagrams according to embodiment 6 of the present invention, fig. 4 is a diagram illustrating an overall configuration of an automatic remote monitoring and diagnosing system, and fig. 5 is a diagram illustrating another overall configuration of the automatic remote monitoring and diagnosing system according to the embodiment.

In embodiment 1, the measurement data of a plurality of different diagnosis clients are collectively managed and collectively diagnosed by a diagnosis server of a diagnosis executor such as a manufacturer or a protection and maintenance service company. Therefore, the internet is used for communication between a plurality of diagnosis clients and diagnosis executives.

In contrast, embodiment 6 described here shows the configuration of the devices constituting the present remote monitoring system, in other words, the configuration of the network nodes, the same as embodiment 1, and shows an example in which the communication network between the devices is changed in accordance with the status, state, and the like of the monitoring target and the diagnosis requester.

Fig. 4 shows an example of a configuration in which a company a, which is a diagnosis principal, manages and diagnoses data collectively in a main company of the company while monitoring electronic control devices and the like in a plurality of sites (plants) of the company as objects to be monitored. In this case, the electronic control devices and the like to be monitored are present in the company a, the company B, the company C, the factory 1f, respectively. An environmental sensor 2 and a physical sensor 3 are provided in each electronic control device and the like of each plant. The measurement data is transmitted from the environmental sensor 2 and the physical sensor 3 to the wireless server 4 by wireless communication.

The communication network that communicatively connects the wireless server 4 and the diagnosis client 6 is a first LAN5a that is laid in each plant. The company a, the company B, the company a, the company C, the company a, the company B, the company C, the company a, the company 1g, and the company a (head office) are connected to each other through an intranet 13, which is an intra-enterprise LAN installed so as to enable communication only in the company a. Therefore, a communication network that communicably connects each of the diagnosis clients 6 in each plant provided in company a and the diagnosis server 9 provided in company a (head office) 1g is the intranet 13. Further, a communication network that communicably connects the diagnosis server 9 and the knowledge database 11 within company a (head office) 1g is a second LAN5 b.

Other structures are the same as those in embodiment 1 and the like.

Fig. 5 shows an example of the following structure: that is, the electronic control device and the like in the site (plant) of company a, which is a diagnosis requester, and in the intra-a plant 1h, are monitored, and data management and diagnosis are also completed in the same site, that is, the intra-a plant 1 h. In this case, the electronic control device and the like in the company a internal plant 1h are the monitoring target, and the environment sensor 2, the physical sensor 3, the wireless server 4, and the diagnosis client 6 are installed in the company a internal plant 1 h. The diagnosis server 9, the data storage device 10, and the knowledge database 11 are also installed in the company a internal factory 1 h.

The measurement data is transmitted from the environmental sensor 2 and the physical sensor 3 to the wireless server 4 by wireless communication. A first LAN5a is installed in a factory 1h in company a. The communication network communicatively connecting the wireless server 4 and the diagnostic client 6 is the first LAN5 a. The communication network communicatively connecting the diagnostic client 6 with the diagnostic server 9 is also the first LAN5 a. Also, a communication network that communicatively connects the diagnosis server 9 with the knowledge database 11 is also the first LAN5 a. That is, the wireless server 4, the diagnosis client 6, the diagnosis server 9, and the data storage device 10 are all connected via the same communication network, i.e., the first LAN5 a.

Other structures are the same as those in embodiment 1.

The automatic remote monitoring and diagnosis system having the above configuration can be flexibly constructed in accordance with the status, state, and the like of a monitoring target and a diagnosis requester by appropriately changing a communication network for communicably connecting these devices without changing the basic configuration of devices constituting the system, such as sensors, clients, servers, and the like.

That is, when the diagnosis requester does not want to disclose measurement data related to its own monitoring target to another person, it is possible to construct a closed system for only the diagnosis requester. In this case, the system can be flexibly constructed depending on the location and the number of monitoring targets owned by the diagnosis client.

Fig. 4 shows a case where the factories in which the electronic control devices and the like to be monitored are located are distributed and present in various places, and the diagnosis clients. By connecting the sites where the monitoring objects are located with the intranet 13 of the company, there is an advantage that the environment data can be measured and diagnosed in a closed manner within the company, and the environment measurement data is not leaked outside the company. Further, the measurement data of the company can be collectively managed by the head office.

Fig. 5 shows a case where the electronic control device or the like to be monitored is located in only one factory and the diagnosis requester is present. In this case, all the devices constituting the system are disposed only at the plant. Therefore, the environmental data can be measured and diagnosed only in the plant in a closed manner, and the measurement data in the plant is not leaked to the outside of the plant.

On the other hand, with the configuration shown in fig. 1 of embodiment 1, a diagnosis implementer who is requested to perform a diagnosis can automatically and easily collect measurement data of electronic control devices and the like in all places where the diagnosis is performed without human intervention. Therefore, the burden of management and the burden of diagnosis work on the diagnosis implementer can be reduced. Further, since a large amount of measurement data, diagnosis results, and the like can be used, improvements in inference engines, diagnostic algorithms, and failure-related data can be expected. That is, the progress of the knowledge database is contributed, and as a result, the cause specifying ability is improved, and the benefit of both the diagnosis client and the diagnosis executor can be obtained.

Industrial applicability of the invention

The present invention is applicable to an automatic remote monitoring and diagnosis system that monitors the state of equipment such as an electronic control device for plant equipment and plant equipment, and automatically diagnoses whether or not there is an abnormality.

Description of the reference symbols

Claims (8)

1. An automatic remote monitoring and diagnosis system for diagnosing an electronic control device or equipment, comprising:

an environment sensor that measures environment data relating to an installation environment of the electronic control device or the equipment at a measurement cycle set for each measurement element and transmits the measurement data by wireless communication;

a physical sensor that measures physical data relating to the electronic control device or the equipment at a measurement cycle set for each measurement element and transmits the measured data by wireless communication;

a wireless server that collects measurement data transmitted from the environmental sensor and the physical sensor by wireless communication and transmits the collected measurement data at a predetermined time interval;

a diagnostic client communicably connected to the wireless server via a first communication network, collecting the measurement data transmitted from the wireless server via the first communication network, and transmitting the collected measurement data at predetermined time intervals;

a diagnostic server communicably connected to the diagnostic client via a second communication network, receiving the measurement data transmitted from the diagnostic client via the second communication network, and performing diagnosis of the electronic control apparatus or the device based on the received measurement data;

a data storage device that stores the measurement data received by the diagnosis server; and

a knowledge database storing information required for the diagnosis server to perform the diagnosis,

the diagnostic server transmits the result of the diagnosis to the diagnostic client via the second communication network, determines a coping process for a problem when the result of the diagnosis indicates that the electronic control device or the equipment has the problem, and transmits the coping process to the diagnostic client via the second communication network,

the physical sensor includes a first sensor group for measuring voltage and current, and a second sensor group for measuring electromagnetic waves and static electricity,

the first sensor group includes a sensor having a first measurement period of about 10 milliseconds and a sensor having a second measurement period of about 10 nanoseconds shorter than the first measurement period.

2. The automated remote monitoring and diagnostic system of claim 1,

the environmental sensor, the physical sensor, the wireless server, and the diagnosis client are installed in a factory where a diagnosis requester who requests a diagnosis of the electronic control device or the equipment is requested,

the diagnosis server, the data storage device, and the knowledge database are provided on a diagnosis implementer side that is requested to implement the diagnosis,

the first communication network is a LAN installed in the plant of the diagnosis requester,

the second communication network is a communication network using the internet.

3. The automated remote monitoring and diagnostic system of claim 1,

the environmental sensor, the physical sensor, the wireless server, and the diagnosis client are installed in a factory where a diagnosis requester who requests a diagnosis of the electronic control device or the equipment is requested,

the diagnosis server, the data storage device, and the knowledge database are arranged in a head office of the diagnosis client,

the first communication network is a LAN installed in the plant of the diagnosis requester,

the second communication network is an intranet communicably connecting the plant of the diagnosis principal and the head office.

4. The automated remote monitoring and diagnostic system of claim 1,

the environmental sensor, the physical sensor, the wireless server, the diagnosis client, the diagnosis server, the data storage device, and the knowledge database are provided in a factory of a diagnosis requester who requests a diagnosis of the electronic control device or the equipment,

the first communication network and the second communication network are both LANs installed in the plant of the diagnosis client.

5. The automated remote monitoring and diagnostic system of any of claims 1 to 4,

the diagnostic server aggregates the measurement data stored in the data storage device for each predetermined period, outputs the aggregated measurement data as an electronic file, and transmits the electronic file to the diagnostic client via the second communication network.

6. The automated remote monitoring and diagnostic system of any of claims 1 to 4,

the diagnostic server diagnoses deterioration of the electronic control device or the equipment by comparing the measurement data transmitted from the diagnostic client with past measurement data stored in the data storage device, assembles the diagnosis results of the deterioration into a predetermined report format, transmits the diagnosis results of the deterioration into the report format to the diagnostic client via the second communication network, determines a coping process for a problem when the diagnosis result of the deterioration is that the electronic control device or the equipment has the problem, and transmits the coping process to the diagnostic client via the second communication network.

7. The automated remote monitoring and diagnostic system of any of claims 1 to 4,

the diagnostic server detects that an abnormality has occurred in at least one of the environmental sensor, the physical sensor, the wireless server, and the diagnostic client based on the measurement data transmitted from the diagnostic client, and when an abnormality has been detected, transmits a signal indicating that abnormality to the diagnostic client via the second communication network.

8. The automated remote monitoring and diagnostic system of any of claims 1 to 4,

the diagnostic client detects that an abnormality has occurred in at least one of the environmental sensor, the physical sensor, and the wireless server based on the measurement data transmitted from the wireless server, and, when an abnormality has been detected, issues a warning of the abnormality.