JP4011338B2 - Industrial equipment remote monitoring system and apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a remote monitoring system for industrial equipment and a remote monitoring device thereof, and in particular, transmits data information and failure prediction information related to the operation status of the equipment and simultaneously transmits information related to equipment repair and purchase. The present invention relates to a remote monitoring system and a remote monitoring device for industrial equipment which are intended to improve the convenience of equipment managers.
[0002]
[Prior art]
Conventionally, various proposals have been made regarding remote monitoring of industrial equipment. For example, in Japanese Patent Laid-Open No. 11-168869, if there is an abnormality in equipment, a notification is made to the terminal device side via an analog telephone network via an automatic notification device. In order to prevent a high price if the number of notifications repeats as the distance from the automatic notification device to the terminal device increases, the Internet is used as a communication means after the access point and only requires a call fee determined by a contract with the provider An automatic notification device configured to transmit abnormality information or the like is disclosed.
[0003]
Japanese Patent Application Laid-Open No. 11-177576 discloses a monitoring system that performs data transmission / reception between a monitoring control device and a monitored control device via a communication cable, and monitors target equipment in the monitored control device. In order to reduce the communication cable cost and the like, a wireless monitoring system is disclosed in which transmission and reception are performed between a monitored device and a monitoring device that operates and manages a monitoring facility via a wireless communication line.
[0004]
Further, JP-A-11-266328 discloses an automatic notification system. This automatic notification system is a device that reports abnormal states detected by various sensors in order to monitor the status of each equipment installed on the site of the monitored equipment, such as unmanned robot factory equipment, and is a terminal of the monitoring center in advance. In accordance with the data set in the above, an automatic notification device that reads out data of an area to be referred to by the blog programmable controller, compares it with a determination standard, and automatically reports when it is determined to be abnormal is shown.
[0005]
[Problems to be solved by the invention]
As shown in the above-mentioned conventional publication, monitoring systems and monitoring devices that monitor abnormal states of industrial equipment and facilities and automatically transmit abnormal data information to the monitoring center have been demonstrated. However, nothing has been reported yet for the convenience of the administrator on the monitoring center side by transmitting transmission data as shown in the following items.
[0006]
(1) Compile the monitoring data in a daily report, weekly report, etc., and report the operating status of the equipment / equipment to the administrator.
(2) Based on the monitoring data, the failure prediction information of the monitoring target device is reported to the administrator in advance.
(3) Based on the monitoring data, when the failure prediction information of the monitoring target device is reported to the administrator in advance, the maintenance information of the monitoring target device and the device product information are simultaneously reported.
(4) When an attempt is made to repair or purchase a device based on the above maintenance information or device product information received by the administrator, the repair request information or product quotation request information is automatically displayed as a repair agent or device. It is sent to the seller.
(5) Billing for acts of (1) to (4)
That is, in the monitoring of the operating status of the industrial equipment remote monitoring device, it is difficult to grasp the operating status of the equipment / equipment as a whole by reporting only the abnormal state, the time of occurrence, etc.
[0008]
Further, there is a problem that the response when the monitored device suddenly causes an accident is delayed when the failure prediction information is not reported in advance.
[0009]
Furthermore, if maintenance information and device product information for monitored devices are not reported, it is not only possible to quickly respond to device repairs and purchases, but also troublesome product requests for requests and repairs at the time of repair requests and purchases. There was a problem that repair, purchase, and billing of remote monitoring target devices / equipment could not be performed quickly and accurately.
[0010]
The present invention has been made to solve the above problems, and the problem to be solved by the invention is that the administrator receives the above-mentioned various data, and the benefits and services received by the device administrator and the service. The present invention provides a system and an apparatus with improved convenience for consideration expenditure.
[0011]
[Means for Solving the Problems]
The present invention according to claim 1 relates to data relating to the operating state of industrial equipment / equipment detected by a sensor disposed in the vicinity of the industrial equipment / equipment or at least one of a wired line or a wireless line. In a remote monitoring system for industrial equipment that is sent to the manager of industrial equipment / equipment via a line, the sensor detects data related to the operational status of the industrial equipment / equipment and measures the operational status. When the value does not exceed the predetermined threshold, the monitoring result data is transmitted every first time. When the value exceeds the predetermined threshold, the monitoring result data is transmitted every second time shorter than the first time. In the state where the monitoring result data is transmitted every second time and when the abnormal state is detected continuously for a predetermined number of times by the sensor, the failure prediction information of the industrial device / equipment is transmitted, and the second Monitor every third time shorter than the hour Sends the result data, the pre-failure prediction information of said product industry for equipment and facilities based on the data relating to the operating state detected by the sensor and reported to the administrator, industrial equipment and facilities of the operation that was further detected The present invention provides a remote monitoring system for industrial equipment characterized in that comprehensive data information obtained by integrating data relating to a state over a predetermined period such as daily report or weekly report is reported to an administrator .
[0012]
The present invention according to claim 2 is an industrial equipment remote monitoring system according to claim 1, wherein the administrator is automatically charged according to the usage of the remote monitoring system.
[0013]
The present invention according to claim 3 reports the maintenance information of industrial equipment / facility and / or equipment product information at the same time when prior failure information is reported to the manager. The remote monitoring system for industrial equipment according to Item 2.
[0014]
According to the fourth aspect of the present invention, when an attempt is made to repair a device or purchase a device based on maintenance information and / or device product information received by an administrator, repair request information and product quotation request information are automatically provided. The remote monitoring system for industrial equipment according to claim 3, wherein the remote monitoring system is sent to a repair shop or equipment sales dealer.
[0015]
In the present invention according to claim 5, the operation data relating to the operating state of the industrial equipment / equipment is detected by the monitored means by the sensor disposed in the vicinity of the industrial equipment / equipment, or the wired line or the wireless line. In a remote monitoring device for industrial equipment that transmits operational data to the monitoring means on the manager side of the industrial equipment / facility via at least one or more lines, the sensor relates to the operating status of the industrial equipment / facility. When the data is detected and the measured value of the operating state does not exceed the predetermined threshold, the monitoring result data is transmitted every first time. When the measured value exceeds the predetermined threshold, it is shorter than the first time. In the state where monitoring result data is transmitted every second time and monitoring result data is transmitted every second time, when an abnormal state is detected continuously for a predetermined number of times by the sensor, Send failure prediction information, second time Remote transmits a short third monitoring result data every time, the sensor has an overall data information creation means comprehensive period of daily, weekly, etc. data information relating to the operating state of the industrial equipment and facilities detected Thus, the industrial data remote monitoring apparatus is characterized in that the total data information obtained by the total data information creating means is transmitted to the manager side of the monitoring means.
[0016]
In the present invention according to claim 6, the operation data relating to the operating state of the industrial equipment / equipment is detected by the monitored means by the sensor disposed in the vicinity of the industrial equipment / equipment, or the wired line or the wireless line. In a remote monitoring device for industrial equipment that transmits operational data to the monitoring means on the manager side of the industrial equipment / facility via at least one or more lines, the sensor relates to the operating status of the industrial equipment / facility. When the data is detected and the measured value of the operating state does not exceed the predetermined threshold, the monitoring result data is transmitted every first time. When the measured value exceeds the predetermined threshold, it is shorter than the first time. In the state where monitoring result data is transmitted every second time and monitoring result data is transmitted every second time, when an abnormal state is detected continuously for a predetermined number of times by the sensor, Send failure prediction information, second time Remote transmits a short third monitoring result data every time, has a failure prediction creating means for creating a pre-failure prediction information industrial equipment and equipment based on the operation data relating to the operating condition detected by the sensor, This is a remote monitoring device for industrial equipment, characterized in that prior failure prediction information obtained by this failure prediction information creating means is transmitted to the manager side.
[0017]
According to the industrial equipment remote monitoring system and the apparatus thereof according to claims 1 to 6, a report such as a daily report and a monthly report on the operation status of the equipment is automatically created and issued, and the labor of the equipment manager , Equipment management costs can be reduced. In addition, it is possible to predict failures over a medium to long-term span based on a database accumulated on the operating status and failure status of equipment, avoiding unforeseen circumstances such as production line shutdowns due to sudden equipment failures. Can result in reduced production costs. In addition, information related to maintenance and new equipment is automatically collected in conjunction with the failure status of equipment, and repair requests and parts ordering work are executed based on the collected information, reducing equipment management work and management costs. The effect that can be produced.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, one embodiment of the present invention will be described in detail with reference to FIG. FIG. 1 is a system diagram showing the overall configuration of a remote monitoring system for industrial equipment.
[0019]
In FIG. 1, reference numeral 1 is a device to be monitored, such as a factory, plant machine, unmanned robot factory facility, refrigeration facility, boiler facility, water supply facility, building disaster prevention facility, unmanned contract machine, substation, power plant facility, etc. These constitute monitored equipment / equipment.
[0020]
A sensor element 2 is attached to the monitored device 1 on the monitored means 22 side. Alternatively, the detection signal of the sensor element 2 disposed in the vicinity of the monitoring target device (hereinafter referred to as device) 1 is supplied to the transceiver 4 in the detection means 5 through the preamplifier 3 in the detection means 5. The signal is received by the antenna 7 on the side of the signal amplifier 8 disposed in the vicinity of the device 1 via the antenna 6.
[0021]
The above configuration shows a configuration in the case where a sufficient output signal can be obtained from the preamplifier 3. Usually, as indicated by a virtual line, the sensor element 2 → the preamplifier 3 → the signal amplifier 8 is configured to transmit a signal by wire. Is done.
[0022]
An analog signal from the signal amplifier 8 is converted into digital data through an ADC (analog-digital converter) in an interface (I / F) 9 and is mounted on a microcomputer (hereinafter referred to as CPU ₁ ) 10 or It is stored in synchronization with the time signal calculating unit (ALU) or the like occurs ROM is normally incorporated in the CPU ₁ 10 in a pre-specified sampling time the CPU ₁ 10, in the memory 11 such as RAM. And a display unit such as CRT is not operated unit 12 and shown such as a keyboard to CPU ₁ 10. The output data of the CPU ₁ 10 is output to the transceiver 13.
[0023]
The digital output data from the CPU ₁ 10 is supplied to the transceiver 13 in the form of analog or digital. In order to perform analog conversion, the signal is supplied to the analog transmitter / receiver 13 via an ADC (analog-digital converter) or the like (not shown), and the monitoring signal information on the monitored means 22 side via the antenna 14 is supplied to the monitoring means 23 side. The signal is transmitted as radio signal information to the antenna 15 on the transceiver 16 side through a communication line 30 such as PHS.
[0024]
Alternatively, it is digitally transmitted to the communication terminal device 16 'via a communication line 30 that forms a wired line such as the Internet.
[0025]
Monitoring signal information transmitted to the transmitter 16 or the communication terminal device 16 'of the monitoring unit 23 side through the CPU ₁ 10 of the monitoring unit 22 side with a real-time or some time delay, the transceiver 16 or communication terminal device 16 'and stored in a memory 18 such as a ROM or RAM that the CPU ₂ 17 normally has via a microcomputer 17 (hereinafter referred to as CPU ₂ ). The CPU ₂ 17 has an operation unit 19 such as a keyboard and a display unit 12 such as a CRT or LCD.
[0026]
In some cases, the monitoring communication information may be directly transmitted via a mobile phone or a personal digital assistant (PDA) 24 owned by the administrator 21.
[0027]
When the monitoring signal information stored in the memory 11 is determined on the basis of the failure criterion software monitored device 1 which has been previously installed on the CPU ₁ 10 is numerical processing in CPU ₁ 10 is in the failure state If the operation is continued in the future, failure prediction information such as when a failure will occur is transmitted.
[0028]
Monitoring signal information and failure information of the monitored device 1 is linked to CPU ₂ 17 and memory 18, failure prediction information of each of the monitored device 1 is updated daily, highly accurate failure prediction information is achieved ing. The monitoring target device 1 of the daily report creation period reports, such as weekly also carried out by these CPU ₂ 17.
[0029]
In addition, when transmitting the failure prediction information to the administrator, the maintenance information and device product information of the monitoring target device 1 are simultaneously reported, but the maintenance information and device product information associated with each of the monitoring target devices 1 are It is managed by the CPU ₂ 17 and is reported to the administrator 21 via the communication line 30 such as the Internet. When each information is newly updated, the updated information is collected via the Internet or the like and stored in the memory 18. To be recorded. When the administrator 21 accesses the maintenance information and product device information transmitted from the administrator 21, a home page on which the maintenance information and product device information is posted is displayed on the information terminal device 24 such as a PDA owned by the administrator 21. The administrator 21 can access the information desired.
[0030]
FIG. 2 shows a communication system in another embodiment in which the remote monitoring system of the present invention is applied to a self-operated local PHS (Personal Handyphone System). The sensor element 2 is provided with a signal amplifier 8 and a PHS transceiver 25 that transmits the amplified signal. The PHS transceiver 25 transmits signals to terminals 26 installed at various locations on the premises. A signal from each terminal 26 is transmitted to a PBX (Private Branch Exchange) 29 via a repeater 28. A general monitoring processing system 29 that executes processing such as data monitoring, collection, recording, analysis, and material creation is connected to the PBX 28 on the premises. Further, the PBX 28 is connected to the PHS terminal 33 owned by each person via the repeater 27 and the terminal 26. Further, when a public line 30a such as the Internet is connected to the general monitoring system 29, and monitoring signal information measured by a sensor element is distributed to the information terminal device 31 such as a personal computer owned by the contractor via the public line 30a. There is also. Furthermore, it is configured to connect to a Web site 30a operated by a maintenance company or an equipment company via a public line 30a, and automatically obtain and distribute information on maintenance of the monitored device 1 and new products.
[0031]
FIG. 3 shows a system diagram of a communication system in another embodiment in which the remote monitoring system of the present invention is applied to a public PHS. The sensor element 2, the signal amplifier 8, the PHS transmitter / receiver 25 for transmitting the amplified signal, the terminals 26 installed at various locations on the premises, and the repeater 27 are the same as in FIG. 2, and are connected from the repeater 27 to the public PHS line 34. To do. The monitoring signal information is transmitted to a DSU (Digital Service Unit) 36 directly from the public PHS line 34 or via the public ISDN line 35. Further, the monitoring signal information and various data from the comprehensive monitoring system 29 detailed in FIG. 2 are transmitted via the terminal adapter 37. When reporting directly to the contractor's PHS terminal device 31 from the public PHS line 34, or when reporting to the information terminal device 31 owned by the contractor via the public ISDN line 35 and the Internet line 30a, and further In some cases, after the information is comprehensively analyzed and judged by the monitoring system 29, the information is issued to the information terminal 31 of the contractor. It is connected to a website 32 operated by a maintenance company or equipment company through a public line 30a such as the Internet, and is configured to automatically obtain and distribute information on maintenance of the monitored device 1 and new products. This is the same as FIG.
[0032]
Hereinafter, based on FIG. 3, the operation in the case of monitoring the failure and the operating state of the motor in the factory line will be described. For example, 80 motors are operating in the business site owned by the contractor. In this case, a failure of one motor leads to a stop of the entire line. Must be detected and switched to a substitute motor. For this reason, the sensor elements 2 are installed in all 80 motors each assigned a management number. In each motor, the temperature of the bearing portion and the vibration state of the rotating shaft are constantly measured, and the measurement data is stored in a memory (not shown) attached to the sensor element 2 (FIG. 4, first step ST ₁ ).
[0033]
The operating state of the motor is classified into a normal state, a transition state, and an abnormal state. A threshold value is set for each level for both temperature and vibration and is compared with the measured value (second step ST ₂ ). When the measurement results of both the temperature and vibration state are in a normal state, such as NO in the third step ST ₃ , the measurement results are sent to the general monitoring system 29 once an hour from the sensor element 2 attached to each motor. It is transmitted (fourth step ST ₄ ).
[0034]
Temperature and any measurement result of the vibration state exceeds the threshold value in the normal state as in YES of the third step ST _3, upon entering the transition state (abnormal state), the transmission of the measurement result is once every 10 minutes (fifth step ST _5). When the measurement result transmitted once every 10 minutes is in the transition state three times in succession (sixth step ST ₆ ), the general monitoring system 29 warns that the corresponding motor needs to be inspected. Is transmitted (seventh step ST ₇ ). When the warning is sent, the person in charge goes to the motor installation location for on-site observation and emergency repair of the motor operation (8th step ST ₈ ), and the transmission of the measurement result is once per minute. up (ninth step ST _9).
[0035]
A simple response such as a lubricating oil supply, when the operating state of the motor returns to the normal state (YES in the tenth step ST _10), the transmission of the fourth is returned to the step ST ₄ measurement results once / Return to 1 hour. If the operation state does not recover due to the emergency repair of the person in charge and the measurement result changes from the transition state to the abnormal state, an alarm is transmitted from the general monitoring system 29 to the information terminal 33 such as PHS carried by the person in charge. Then, switching to an alternative motor for replacement is performed (12th step ST ₁₂ ).
[0036]
Note that calling or warning or alarm, changing the measurement conditions with the change in the operating state of the motor is performed by the firmware written in the ALU of CPU ₁ 10 incorporated in the monitoring unit 22 side, i.e. Overall It is also possible to send a measurement condition change command directly from the monitored means 22 instead of the monitoring system 29. When the replacement motor is replaced (12th step ST ₁₂ ), the operation state of the replacement motor is confirmed (14th step ST ₁₄ ). In this initial operation state, transmission is performed once per minute (13th step). ST ₁₃ ). After that, in order to correct or replace the abnormally operating motor, it is connected to the Web site 32 of the supplier in charge through the general monitoring system 29, and processing such as ordering repaired products, requesting repairs, and requesting new product quotes is executed. (15th step ST ₁₅ ).
[0037]
In the comprehensive monitoring system 29, based on the measurement results sequentially transmitted from the sensor elements 2 attached to the respective motors, the above-mentioned warnings, warnings, and results after repair are combined into daily reports, It is a system that automatically creates a monthly report and transmits it via the Internet or the like (16th step ST ₁₆ ).
[0038]
In addition, the measurement results and failure information accumulated over a long period of time in the integrated monitoring system are accumulated as a database. By comparing the measurement results sequentially transmitted from the sensor element 2 with this database, the determination is made in the medium to long term. Failure prediction information is created.
[0039]
Report creation and transmission, creation and transmission of failure prediction information, transmission and reception of various information related to operation status, maintenance linked to device operation status, automatic collection and ordering of new equipment, etc. It is also possible to charge a predetermined fee to the contractor for service activities such as automatic processing.
[0040]
The CPU that outputs the above-described failure prediction information can use a failure prediction system that uses a self-learning method in which the determination accuracy related to the operating state of the device improves as the data storage amount increases. In addition, the issuance of data to be aggregated during periods such as daily reports and monthly reports is largely dependent on data storage equipment and data calculation / analysis / determination functions.
[0041]
【The invention's effect】
The effects of the remote monitoring system for industrial equipment and its apparatus according to the present invention are listed below.
1) A report such as a daily report and a monthly report on the operation status of the apparatus is automatically created and issued, and the labor of the apparatus manager and the apparatus management cost can be reduced.
2) Based on the accumulated database on the operation status and failure status of equipment, it is possible to predict failures over a medium to long term span, avoiding unforeseen situations such as production line shutdowns due to sudden equipment failures. Can result in reduced production costs.
3) In conjunction with the failure status of equipment, information on maintenance and new equipment is automatically collected, and repair requests and parts ordering work are executed based on the collected information, reducing equipment management work and management costs. it can.
[Brief description of the drawings]
FIG. 1 is an overall system diagram of an industrial equipment remote monitoring system and apparatus according to an embodiment of the present invention.
FIG. 2 is a system diagram showing an example of a communication system to which the industrial equipment remote monitoring system of the present invention and its apparatus are applied.
FIG. 3 is a system diagram showing one example of another communication system applied to the industrial equipment remote monitoring system of the present invention and its apparatus;
FIG. 4 is a flowchart for explaining the system operation of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Monitored device, 2 ... Sensor element, 3 ... Preamplifier, 4 ... Wireless transceiver, 5 ... Amplifier, 10 ... Microcomputer (CPU ₁ ), 11, 18 ... Memory, 13 ... Transmitter / receiver, 17 ... microcomputer (CPU ₂ ), 21 ... device manager, 25 ... PHS transmitter / receiver, 26 ... terminal, 27 ... repeater, 28 ... PBX, 29 ... total monitoring system, 30 ... Communication line, 30a ... Public line (Internet), 31 ... Information terminal device owned by contractor, 32 ... Web site of maintenance company, 33 ... PHS terminal, 34 ... Public PHS line, 35 ... Public ISDN line, 36 ... DSU, 37 ... Terminal adapter

Claims (6)

Data relating to the operating state of the industrial equipment / equipment detected by the industrial equipment / equipment or a sensor disposed in the vicinity thereof is transmitted to the industrial equipment via at least one or more of a wired line or a wireless line. In the remote monitoring system for industrial equipment that is sent to the manager of equipment and facilities,
When the sensor detects the data related to the operating state of the industrial equipment / equipment, and the measured value of the operating state does not exceed a predetermined threshold, the monitoring result data is transmitted every first time, When the predetermined threshold is exceeded, the monitoring result data is transmitted every second time shorter than the first time,
In the state where the monitoring result data is transmitted every second time, when the abnormal state is detected continuously by the sensor a predetermined number of times, failure prediction information of the industrial equipment / facility is transmitted, and the second Send the monitoring result data every third time shorter than
A pre-failure prediction information of said product industry for equipment and facilities based on the data relating to the operating state detected by the above Symbol sensor to report with respect to the administrator, to further detect the operating state of the industrial equipment and facilities A remote monitoring system for industrial equipment, characterized in that comprehensive data information obtained by integrating the related data in a predetermined period such as daily report or weekly report is reported to the administrator .   2. The remote monitoring system for industrial equipment according to claim 1, wherein the administrator is automatically charged according to a usage pattern of the remote monitoring system.   3. The maintenance information or / and the equipment product information of the industrial equipment / facility are simultaneously reported when the prior failure information is reported to the manager. Remote monitoring system for industrial equipment.   When an attempt is made to repair a device or purchase a device based on the maintenance information or / and the device product information received by the administrator, repair request information or product quotation request information is automatically displayed as a repair agent or device sales. The remote monitoring system for industrial equipment according to claim 3, wherein the remote monitoring system is transmitted to a contractor. Operational data related to the operating state of the industrial equipment / equipment is detected by the monitored means by a sensor disposed in the vicinity of the industrial equipment / equipment, and at least one line of a wired line or a wireless line is detected. In the industrial equipment remote monitoring device for transmitting the operation data to the monitoring means on the manager side of the industrial equipment / facility via
When the sensor detects the data related to the operating state of the industrial equipment / equipment, and the measured value of the operating state does not exceed a predetermined threshold, the monitoring result data is transmitted every first time, When the predetermined threshold is exceeded, the monitoring result data is transmitted every second time shorter than the first time,
In the state where the monitoring result data is transmitted every second time, when the abnormal state is detected continuously by the sensor a predetermined number of times, failure prediction information of the industrial equipment / facility is transmitted, and the second Send the monitoring result data every third time shorter than
Comprehensive data information creation means that integrates the data information related to the operational state of the industrial equipment / equipment detected by the sensor with a period of daily reports, weekly reports, etc.,
A remote monitoring apparatus for industrial equipment, wherein the total data information obtained by the total data information creating means is transmitted to the manager side of the monitoring means. Operational data related to the operating state of the industrial equipment / equipment is detected by the monitored means by a sensor disposed in the vicinity of the industrial equipment / equipment, and at least one line of a wired line or a wireless line is detected. In the industrial equipment remote monitoring device for transmitting the operation data to the monitoring means on the manager side of the industrial equipment / facility via
When the sensor detects the data related to the operating state of the industrial equipment / equipment, and the measured value of the operating state does not exceed a predetermined threshold, the monitoring result data is transmitted every first time, When the predetermined threshold is exceeded, the monitoring result data is transmitted every second time shorter than the first time,
In the state where the monitoring result data is transmitted every second time, when the abnormal state is detected continuously by the sensor a predetermined number of times, failure prediction information of the industrial equipment / facility is transmitted, and the second Send the monitoring result data every third time shorter than
It has failure prediction creation means for creating advance failure prediction information of the industrial equipment / facility based on operation data related to the operation state detected by the sensor, and the advance failure obtained by the failure prediction information creation means A remote monitoring device for industrial equipment, wherein prediction information is transmitted to the manager side.

Images