JP2016091414A - Failure estimation device, failure estimation database device, failure estimation program, failure estimation database program, and failure estimation system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a failure estimation device, failure estimation database device, failure estimation program, failure estimation database program, and failure estimation system which estimate a failure of a module.SOLUTION: According to an embodiment, the failure estimation device is a failure estimation device for estimating the failure possibility of each module of a programmable controller. The failure estimation device includes an information collection part for collecting energizing time data of each module, environmental condition data of an environment in which a module is established and failure existence/absence data of the module, and an information analysis part for reading a database including environmental coefficient data representing a deterioration degree of the module to an environmental condition from the module, and calculating the failure possibility of each module. The database is updated on the basis of the energizing time data, environmental coefficient data and failure existence/absence data which are collected from a plurality of modules belonging to a plurality of programmable controllers and are respectively associated with the plurality of modules.SELECTED DRAWING: Figure 1

Description

  Embodiments described herein relate generally to a failure estimation device, a failure estimation database device, a failure estimation program, a failure estimation database program, and a failure estimation system.

  In a programmable controller including a plurality of modules, it is difficult to specify which module is abnormal due to an abnormal state. For this reason, it is difficult to determine which module should be arranged and replaced, and it may be necessary to arrange all the modules that are likely to fail.

  The cause of the failure of each module constituting the programmable controller is greatly affected by the state of the environment in which the module is installed, for example, the ambient temperature, relative humidity, and the quality of the applied power source. It is generally difficult to determine which environmental conditions are likely to cause failure or deterioration in which modules. In addition, these environmental conditions are often involved not only when they become module failure factors alone, but also in many cases, making it more difficult to identify the failure factors of the module. Objectively knowing the degree of involvement of environmental conditions with the failure factor will lead to the identification of the module failure, and will be useful for improving the quality of the module. There are similar problems in performing device deterioration diagnosis including a programmable controller, and several proposals have been made to solve such problems (for example, Patent Document 1).

JP 2002-207837 A

  In Patent Document 1, in order to diagnose a failure or deterioration of a device, an environmental evaluation point representing how much each environmental condition contributes to the failure or deterioration of the device is defined for a plurality of environmental conditions. A technique that describes the degree of deterioration according to the size of the environmental evaluation point is described. However, in this technology, it is necessary to create a model for quantitatively indicating the deterioration status of members, parts, etc. constituting the apparatus, and in order to use the model, deterioration correlation data of metal materials, etc. Need to get. When a model is created or deterioration correlation data is acquired, various problems such as measurement accuracy problems and man-hours for data acquisition occur. In the case of a programmable controller, the module configuration is diverse and complex, and each module itself uses many members, parts, etc., and verifies how well the actual failure and deterioration states match the quantification model. There is a problem that it is difficult.

  An object of an embodiment is to provide a failure estimation device, a failure estimation database device, a failure estimation program, a failure estimation database program, and a failure estimation system that can easily and accurately estimate a module failure.

  The failure estimation device according to the embodiment is a failure estimation device that estimates the possibility of failure for each module of the programmable controller. The failure estimation device includes, from the module, an energization time data for each module, environmental condition data of an environment where the module is installed, and an information collecting unit that collects failure presence / absence data of the module, and deterioration of the module with respect to the environmental condition An information analysis unit that reads a database including environmental coefficient data representing the degree of the failure and calculates the possibility of failure for each module. The database is collected from a plurality of modules included in a plurality of programmable controllers including the programmable controller, and is based on the energization time data, the environmental coefficient data, and the failure presence / absence data associated with each of the plurality of modules. Updated.

  In the failure estimation apparatus according to the embodiment, the database is updated based on the number of failures of modules and the environmental element data collected, so that the possibility of module failure is estimated more accurately according to the actual situation. be able to.

1 is a schematic block diagram illustrating a failure estimation device according to a first embodiment. 1 is a schematic block diagram illustrating a failure estimation system including a failure estimation device and a failure estimation database device. It is a figure which shows the example of the threshold value table for environmental evaluation which is a part of database for performing failure estimation with a failure estimation apparatus. It is a figure which shows the example of the weighting table for environmental evaluation which is a part of database for performing a failure estimation with a failure estimation apparatus. It is a flowchart for demonstrating an example of operation | movement of a failure estimation apparatus. It is a figure which illustrates the possibility of a failure for every module of the same programmable controller. It is a typical block diagram which illustrates the failure estimation database apparatus concerning a 2nd embodiment. It is a flowchart for demonstrating an example of operation | movement of a failure estimation database apparatus. It is a figure which shows an example of the database used for a failure estimation apparatus.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the size ratio between the parts, and the like are not necessarily the same as actual ones. Further, even when the same part is represented, the dimensions and ratios may be represented differently depending on the drawings.
Further, in the present specification and each drawing, the same reference numerals are given to the same elements as those described above with reference to the previous drawings, and detailed description thereof will be omitted as appropriate.

(First embodiment)
FIG. 1 is a schematic block diagram illustrating a failure estimation apparatus according to this embodiment.
FIG. 2 is a schematic block diagram illustrating a failure estimation system including a failure estimation device and a failure estimation database device.

  As shown in FIG. 1, the failure estimation apparatus 10 includes an information collection unit 1, an information analysis unit 2, a CPU 3, an input interface 4, an input unit 5, an output interface 6, an output unit 7, and a communication interface. 8a and 8b and a storage unit 9. The failure estimation device 10 is, for example, a computer terminal. As shown in FIG. 1, in the failure estimation device 10, the CPU 3 may include an information collection unit 1 and an information analysis unit 2. For example, the functions of the information collecting unit 1 and the information analyzing unit 2 are realized by sequentially executing a program that is read from the storage unit 9 in accordance with an instruction of the CPU 3 and developed on the memory of the CPU 3. Also good.

  As shown in FIG. 1, the information collection unit 1 and the information analysis unit 2 are connected to an input interface 4, and data and the like are input by an input unit 5 such as a keyboard. The information collection unit 1 and the information analysis unit 2 are connected to the output interface 6 and output data and the like to the output unit 7 such as a monitor via the output interface 6. The information collection unit 1 and the information analysis unit 2 are connected to the modules 21a to 21d of the programmable controller 20 (hereinafter also referred to as PLC 20) via the communication interface 8a, and exchange data. The information collection unit 1 and the information analysis unit 2 access the database 51a via the communication interface 8b. The information collection unit 1 and the information analysis unit 2 are connected to the storage unit 9 and exchange data and the like.

  As shown in FIG. 2, the information collection unit 1 measures the accumulated energization time data of the modules 21 a to 21 d constituting the PLC 20 and the conditions of the environment where the PLC 20 is installed via the first communication network 40. Measurement data from the sensors 31a to 31e to be collected is collected. The information collection unit 1 collects information on whether any of the modules 21a to 21d has failed through the first communication network 40. The failure information of the modules 21a to 21d may be input to the information collecting unit 1 via the input interface 4 from the input unit 5 such as a keyboard.

  Based on the data collected by the information collection unit 1 and the data stored in the database 51a, the information analysis unit 2 performs the environmental degradation point d (s), the cumulative environmental degradation point D (S), and the cumulative energization time degradation point. Calculate DL (T). The environmental degradation point d (s) is obtained by quantifying the degree of module degradation accelerated by environmental conditions at the timing s when the information collecting unit 1 collects data. The accumulated environmental degradation point D (S) is integrated over all the timings at which the environmental degradation point d (s) is collected, and is quantified as the accumulated degree of degradation. The accumulated energization time degradation point DL (T) is a numerical value as the degree of degradation due to the environmental conditions and the energization time in consideration of the accumulated energization time for each module to the accumulated environment degradation point D (S).

  Based on the accumulated energization time degradation point DL (T), the information analysis unit 2 selects a module having a high possibility of failure from the modules 21a to 21d, and issues an instruction to display that there is a possibility of failure. Send to that module.

  As shown in FIG. 1, the CPU 3 of the failure estimation apparatus 10 is connected to an input interface 4, an output interface 6, communication interfaces 8 a and 8 b, and a storage unit 9. These may be individually connected to the CPU 3 or may be connected via a bus installed inside. For example, the CPU 3 loads a program from the storage unit 9 and executes each step of the program. According to each step of the program, the input interface 4, the output interface 6, the communication interfaces 8a and 8b, and the storage unit 9 are appropriately controlled.

  The input interface 4 is connected to the input unit 5. The input unit 5 includes input devices such as a keyboard, a mouse, and a scanner, for example. Data input from the input unit 5 is transmitted to the CPU 3 via the input interface.

  The output interface 6 is connected to the output unit 7. The output unit 7 includes an output device such as a monitor or a printer. In accordance with a command from the CPU 3, appropriate data is output to the output unit 7 via the output interface 6.

  The communication interface 8a is connected to the first communication network 40. The first communication network 40 is an in-factory LAN using, for example, Ethernet (registered trademark). The failure estimation apparatus 10 is connected to the sensor module 30 including the modules 21a to 21d and the various sensors 31a, 31b, 31c, 31d, and 31e constituting the PLC 20 installed in the factory via the first communication network 40. And exchange data with them. The first communication network 40 may be wired or wireless. A plurality of communication networks may be connected. The failure estimation device 10 only needs to be connected to the modules 21a to 21d and the various sensors 31a to 31e of the PLC 20, and these communication interfaces are selected according to the settings of the communication network.

  The communication interface 8b is connected to the second communication network 42. The second communication network 42 is, for example, the Internet. The failure estimation device 10 is connected to a failure estimation database device 50 outside the factory via the second communication network 42 and exchanges data with the failure estimation database device 50. Needless to say, the failure estimation apparatus 10 can be connected to another computer or server via the second communication network 42. Of course, it does not matter whether the second communication network 42 is prioritized, wireless, or a combination thereof. The communication interface 8b is selected according to the network configuration.

  Below, the whole structure of the failure estimation system 100 is demonstrated. As shown in FIG. 2, the failure estimation system 100 includes a failure estimation device 10, a PLC 20, a first communication network 40, a failure estimation database device 50, and a second communication network 42.

  The failure estimation device 10 is connected to the modules 21 a to 21 d of the PLC 20 and the sensors 31 a to 31 e of the sensor module 30 via the first communication network 40. The failure estimation device 10 is connected to the failure estimation database device 50 via the second communication network 42.

  The PLC 20 includes a plurality of modules 21a to 21d. The modules 21a to 21d are connected to the first communication network 40, respectively. The module 21a includes a communication interface 22a, a display unit 23a, a storage unit 24a, and an energization time output unit 25a. The communication interface 22a is connected to the display unit 23a and the storage unit 24a.

  The display unit 23a receives and displays data indicating the possibility of failure of the module 21a from the failure estimation device 10 via the first communication network 40 and the communication interface 22a.

  The storage unit 24a is connected to the energization time output unit 25a. The energization time output unit 25a is, for example, a counter, and when the module 21a is powered on and in an energized state, the counter starts and measures the energization time of the module 21a. The storage unit 24a accumulates and stores the time output by the energization time output unit 25a. The storage unit 24a stores the accumulated time that the module 21a is energized. The storage unit 24a needs to store the cumulative energization time even when the module 21a is powered off. For this reason, the storage unit 24a is preferably a writable and nonvolatile memory. The storage unit 24a transmits the cumulative energization time of the module 21a to the failure estimation device 10 via the first communication network 40 and the communication interface 22a in accordance with the transmission request from the failure estimation device 10.

  Since the other modules 21b to 21d are the same as the module 21a, description thereof is omitted. Note that the number of modules included in the PLC 20 is not limited to four as shown in FIG. 1 and can be set to an arbitrary number. The PLC 20 includes modules having various functions. For example, a module such as a DC power supply module that outputs an arbitrary DC voltage, an AC power supply module that outputs an arbitrary AC voltage, and an input module that inputs various sensors is appropriately selected according to the process in which the PLC 20 is used. . In the above description, each of the modules 21a to 21d has a built-in communication interface, but one module has a communication interface, and distributes communication data to other modules in accordance with instructions from the module having the communication interface. However, communication data may be collected from other modules.

  The sensor module 30 includes a plurality of sensors 31 a to 31 e and a communication interface 32. The plurality of sensors 31a to 31e acquire environmental condition data in which the modules 21a to 21d are installed. In the present embodiment, environmental elements are defined as variables representing environmental conditions. The environmental elements representing the environmental conditions include, for example, the temperature 20 (PC) in the panel, humidity RH (%), power noise level Vn (dB), power supply voltage fluctuation value ΔVin (reference value ±%), consumption Current fluctuation value ΔIcc (rated value ±%), power consumption fluctuation value ΔPc (rated value ±%), frequency of instantaneous power interruption (times / 10 minutes), temperature change in panel (° C / 10 minutes), and vibration level F ( dB) is set. The plurality of sensors 31a to 31e are, for example, a temperature sensor, a humidity sensor, a voltage sensor, a current sensor, and an acceleration sensor.

  The communication interface 32 is connected to a plurality of sensors 31a to 31e. The communication interface 32 converts analog physical quantities such as temperatures acquired by the plurality of sensors 31 a to 31 e into digital signals, and transmits data to the failure estimation device 10 via the first communication network 40. The failure estimation apparatus 10 calculates data corresponding to environmental elements such as the power supply voltage fluctuation value ΔVin from the data representing the transmitted voltage value and the like.

Next, the database 51a will be described.
FIG. 3 is a diagram illustrating an example of an environmental evaluation threshold table that is a part of a database for performing failure estimation by the failure estimation apparatus.
FIG. 4 is a diagram illustrating an example of an environment evaluation weighting table which is a part of a database for performing failure estimation by the failure estimation apparatus.
The failure estimation device 10 accesses the database 51a included in the failure estimation database device 50 via the second communication network 42. The database 51a includes an environmental evaluation threshold table 200 and an environmental evaluation weighting table 300. Further, as will be described later, the database 51a collects data on threshold levels for environmental evaluation for each environmental element and data on accumulated energization time collected by all failure estimation devices 10 participating in the failure estimation system 100. And data on the presence or absence of a failure. The threshold value data for environmental evaluation, the accumulated energization time data, and the presence / absence of failure are associated with each module.

  As shown in FIG. 3, the environmental evaluation threshold table 200 includes an environmental element number input unit 201, an environmental element name input unit 202, a threshold classification input unit 203, and an environmental evaluation threshold level classification display. Part 204. The environmental evaluation threshold table 200 provides an environmental evaluation threshold level as a rank value for quantifying the degree of deterioration of the module for each environmental element in the environment where the PLC 20 is installed.

  The environmental element number input unit 201 receives an environmental element number i to which a different integer is assigned. The environment element name input unit 202 receives an environment element name corresponding to the environment element i input to the environment element number input unit 201. A threshold value indicating the range of environmental conditions corresponding to the environmental element i is input to the threshold value classification input unit 203. The environmental evaluation threshold level category display unit 204 displays a numerical value indicating the degree of acceleration of the deterioration of the module. The environmental evaluation threshold level category display unit 204 displays an integer corresponding to the threshold value input to the threshold category input unit 203.

  As shown in FIG. 3, an integer from 1 to 9, for example, is set as the number i for identifying the environmental element. The in-board temperature Ta (° C.) of the module is associated with the environmental element 1. The in-panel humidity RH (%) of the module is associated with the environmental element 2 and is similarly associated with other environmental conditions. The range of the environmental conditions in which the modules 21a to 21d are installed is divided into six stages, and corresponding to each range, as shown in the environmental evaluation threshold level division display unit 204, each of 0 to 5 An integer is assigned. The assigned integer value will be referred to as an environmental evaluation threshold level e (i) for the environmental element i. For example, in FIG. 3, the environmental evaluation threshold level e (1) can be assigned to the internal temperature Ta (° C.) as the environmental element 1 as follows.

If Ta <A1 = 20 ° C., e (1) = 0
When Ta <A2 = 30 ° C., e (1) = 1
When Ta <A3 = 40 ° C., e (1) = 2
When Ta <A4 = 50 ° C., e (1) = 3
When Ta <A5 = 60 ° C., e (1) = 4
When 60 ° C. ≦ Ta, e (1) = 5

  Similarly, the range of the relative humidity RH (%) of the module is set in correspondence with the environmental element 2, and the environmental evaluation threshold level e (2) for the environmental element 2 can be assigned.

  An environmental evaluation threshold level e (i) is set on the database 51a for all environmental elements i. The threshold level e (i) for environmental evaluation is a coefficient that becomes a larger value as the environmental conditions are severer, and is a coefficient that indicates how much the environment accelerates the degree of deterioration of the module. At the above-described panel internal temperature Ta, e (1) increases as the temperature rises, and the degree of contribution to deterioration of the module with respect to environmental conditions increases. The association between the environmental condition range and the environmental evaluation threshold value e (i) is input in advance as a fixed value. For all modules, the correspondence between the environmental condition range and the environmental evaluation threshold level e (i) may be the same, or each module corresponds to the environmental evaluation threshold level e (i). A range of environmental conditions may be set. For example, if a module has special parts that are known to accelerate the degradation of the module over other modules over a range of specific environmental conditions, It is possible to associate threshold value data having a larger value than the threshold value data set in this range.

  The environment evaluation weighting table 300 includes an environment element number input unit 301, an environment element name input unit 302, and a weight value input unit 303. The environmental evaluation weighting table 300 provides a coefficient representing the degree to which the environmental element contributes to the deterioration of the module.

  The environment element number input unit 301 receives the environment element input to the environment element number input unit 201 of the environment evaluation threshold value table 200. The environment element name input unit 302 receives an environment element name corresponding to the environment element i input to the environment element name input unit 202 of the environment evaluation threshold value table 200. The weight value input unit 303 receives a coefficient representing the degree to which the environmental element i affects the deterioration of the module. For example, as shown in FIG. 4, the in-panel temperature Ta (° C.) of the environmental element 1 is set to 0.25 as the weight value w (1). The board element humidity RH (%) of the environmental element 2 is set to 0.05 as the weight value w (2). By changing the weight value w (i) corresponding to the environmental element i, it is possible to change the contribution of the deterioration of the module to the environmental element even if the environmental evaluation threshold level e (i) is the same. For example, the contribution of the deterioration of the module to the internal temperature Ta can be set to be larger than the contribution of the deterioration to the internal humidity RH. By changing the weight value, the member used for the module It is possible to reflect the degree of acceptability for the environment such as parts.

  Each weight value w (i) of the environmental evaluation weighting table 300 is initially input as a default value, but is updated in the database update unit 51 based on the collected failure information of all modules. Therefore, the correspondence between the environmental condition and the weight value w (i) may be the same for all modules, but in a normal case, the correspondence is set for each module model name. Therefore, the acceptability with respect to each environmental condition can be reflected for each model name of the module using different members and parts.

  The data of the threshold level e (i) for environmental evaluation for the environmental element i is stored in the database 51a in association with each module together with the data on the presence / absence of failure and the data of the accumulated energization time.

Next, operation | movement of the failure estimation apparatus 10 of this embodiment is demonstrated with reference to a flowchart.
FIG. 5 is a flowchart for explaining an example of the operation of the failure estimation apparatus.

  In step S1, the information collecting unit 1 determines whether or not a specified time T1 has elapsed. The prescribed time T1 sets the frequency with which the failure estimation device 10 updates the database 51a by transmitting each piece of data associated with each module collected by the information collection unit 1 to the failure estimation database device 50. For example, when the database 51a is regularly updated once a day, the specified time T1 is one day (24 hours). In order to transmit data to the failure estimation database device 50 having the database 51a when 24 hours have elapsed, the failure estimation device 10 performs a transmission process in step S12. If 24 hours have not elapsed, the process proceeds to the next step S2. The specified time T1 is not limited to the relative time setting described above, and may be a time setting or a date setting.

  In step S2, the information collecting unit 1 determines whether or not a specified time T2 has elapsed. For the specified time T2, the failure estimation device 10 causes the information collection unit 1 to set the energization time data from the modules 21a to 21d and the environmental evaluation threshold value corresponding to the environmental element from each of the sensors 31a to 31e. Set how often to collect data. The specified time T2 is, for example, 1 hour. When the specified time T2 has elapsed, the process proceeds to the next step S3. If the specified time T2 has not elapsed, the process returns to step S1 and the above-described processing is repeated until the occurrence of an abnormality in the PLC 20 or the modules 21a to 21d is detected. The setting of the prescribed time T2 is not limited to the relative time setting described above, and may be a time setting or a date setting.

  In step S3, the information collection unit 1 collects data for energization time from the modules 21a to 21d and data for setting environmental evaluation threshold values corresponding to the environmental elements from the sensors 31a to 31e.

  In step S <b> 4, the information analysis unit 2 determines which of the threshold value classification input units 203 of the environmental evaluation threshold value table 200 includes the environmental element data based on the sensors 31 a to 31 e. And the information analysis part 2 acquires the value of the threshold level e (i) for environmental evaluation corresponding to the division. For example, e (1) = 2 when the measured value by the sensor of the panel internal temperature Ta (° C.) which is the environmental element 1 is 35 ° C. In this manner, in step S4, the values of all the environmental evaluation threshold levels e (i) are checked for all the modules, and appropriate values are acquired.

  In step S5, the information analysis unit 2 acquires the weight value w (i) for each environmental element i by using the environment evaluation weighting table 300 (FIG. 4).

  In step S6, the information analysis unit 2 calculates the environmental degradation point d (s) at the information collection time point s using the acquired environmental evaluation threshold level e (i) and the weight value w (i). To do. The environmental degradation point d (s) is expressed by the following equation (1).

  Here, e (i) is an environmental evaluation threshold level of the environmental element i, w (i) is a weight value of the environmental element i, and N is the total number of environmental elements to be considered. In the example of FIGS. 3 and 4, N = 9.

  The environmental degradation point d (s) is a numerical value representing the degree of degradation of the module at that time point s, which is calculated every specified time T2. For example, in the environmental evaluation threshold table 200 of FIG. 3, when the in-panel temperature Ta as the environmental element 1 is 35 ° C., the environmental evaluation threshold level e (1) = 2. In the weighting table 300 for environmental evaluation in FIG. 4, the weight value w (1) = 0.25 of the in-panel temperature Ta. Therefore, the term for the environmental element 1 of the environmental degradation point d (s) at that time s is e (1) × w (i) = 2 × 0.25 = 0.5. By accumulating e (i) for all the environmental elements i of the module, the information analysis unit 2 calculates the environmental degradation point d (s) at that time s.

  In step S7, the information analysis unit 2 calculates the accumulated environmental degradation point D (s) using the environmental degradation point d (s). The accumulated environmental degradation point D (s) is calculated by the following equation (2).

  Here, S is the total number of samplings for which data has been acquired.

  The environmental degradation point d (s) is an environmental degradation point at a specific time s. Since the degree of deterioration due to the environmental conditions of the module is considered to increase with each sampling, the degree of progress of the module deterioration is quantified by integrating the environmental deterioration points d (s) at each calculation time.

  In step S <b> 8, the information analysis unit 2 calculates the accumulated energization time degradation point DL (T) considering the accumulated energization time T using the accumulated environment degradation point D (S). The accumulated energization time deterioration point DL (T) considering the accumulated energization time T is calculated by the following equation (3).

  Here, T is the cumulative energization time, and MTBF is the average failure energization time.

  By defining the cumulative energization time deterioration point DL (T) in this way, the degree of deterioration of the module in consideration of the energization time of the module is represented by a numerical value.

  In step S9, the information analysis unit 2 determines whether an abnormality has occurred in the modules 21a to 21d. If an abnormality is detected, the process proceeds to step S10. If no abnormality is detected, the process returns to step S1 and the above steps are repeated.

  In step S10, the information analysis unit 2 estimates in which module a failure has occurred. The information analysis unit 2 outputs the accumulated energization time deterioration points DL (T) for each module calculated by the equation (3) as a list. The information analysis unit 2 calculates the module failure possibility based on the accumulated energization time deterioration point DL (T). For example, as illustrated in FIG. 6, the information analysis unit 2 outputs a deterioration point display table 400 in order to estimate a failure module. The target module display unit 401 displays modules A (21a) to D (21d) that are targets for failure estimation. The accumulated energization time deterioration point display unit 402 displays the accumulated energization time deterioration points DL (T) calculated for the respective modules 21a to 21d for each of the modules 21a to 21d. From the output result by the accumulated energization time deterioration point display unit 402, the module having the largest accumulated energization time deterioration point DL (T) can be displayed as a module having a high possibility of failure. In the case of FIG. 6, the value of the cumulative energization time deterioration point DL (T) of the module D (21d) is shown to be larger than those of the other modules A to C (21a to 21c). In the failure possibility display unit 403, as the possibility of failure for each of the modules 21a to 21d, the accumulated energization time deterioration point DL (T) of each module 21a to 21d is displayed as the accumulated energization time deterioration point DL (T ) Divided by the total value can be displayed.

  In step S11, the information analysis unit 2 transmits a signal indicating that a failure has occurred on the display unit to the module having the largest accumulated energization time degradation point DL (T) via the first communication network 40. . Not only the case where the cumulative energization time deterioration point DL (T) is the largest is selected, but the failure probability value displayed in% may be used. For example, a failure possibility threshold value that is determined to be a failure may be provided in advance, and whether or not there is a failure may be determined based on whether or not this threshold value is exceeded. Not only when the PLC 20 is out of order, but when the cumulative energization time deterioration point DL (T) reaches a predetermined value, it is considered that the deterioration is progressing, so it is necessary to order a module for replacement. It is also possible to display an alert display on the monitor of the failure estimation apparatus 10 or the like.

  In the above description, the PLC 20 and the failure estimation database device 50 are connected via different communication networks 40 and 42, but may be connected to each other using a single communication network. . The database 51a is not limited to being included in the failure estimation database device 50 that is a database server, but is included in the storage unit 9 of the failure estimation device 10 so that the failure estimation device 10 operates as a host. Also good.

  In addition, when the failure estimation device 10 implements the operation according to the above-described procedure by a computer program, the program recorded in the storage medium is installed in the failure estimation device 10 and stored in its own storage unit 9. Can be loaded and executed. Further, for example, it goes without saying that it can also be realized by so-called cloud computing that operates according to a program provided by the failure estimation database device 50 or another application server via the second communication network 42 that is the Internet.

  As described above, in the failure estimation device 10 of the present embodiment, the range of the environmental condition is set as the environmental evaluation threshold level for each environmental element representing the environmental condition in which the modules 21a to 21d of the PLC 20 are installed. In addition, a weight representing the degree of contribution to module degradation is set for each environmental element. By using such a coefficient, the degree of deterioration for each module can be expressed by the accumulated energization time deterioration point DL (T), so it is estimated which module has failed under complex environmental conditions. be able to.

(Second Embodiment)
FIG. 7 is a schematic block diagram illustrating the failure estimation database device according to this embodiment.
As shown in FIG. 7, the failure estimation database device 50 includes a database update unit 51, a CPU 53, an input interface 54, an input unit 55, an output interface 56, an output unit 57, communication interfaces 58a and 58b, A storage unit 59. The failure estimation database device 50 is, for example, a database server. As shown in FIG. 7, in the failure estimation database device 50, the CPU 53 may include a database update unit 51.

  The database update unit 51 is connected to an input interface 54, and data and the like are input by an input unit 55 such as a keyboard. The database update unit 51 is connected to the output interface 56 and outputs data and the like to the output unit 57 such as a monitor via the output interface 56.

  The database update unit 51 is connected to the second communication network 42 via the communication interface 58a, and receives data collected by the failure estimation apparatus 10. The database update unit 51 updates the database 51a based on the received data.

  The database update unit 51 can be connected to another failure estimation apparatus 70 via the communication network 42 and the communication interface 58a which are the Internet. Therefore, the failure estimation database device 50 can be connected to a plurality of failure estimation devices and collect more environmental data and the like.

  The database update unit 51 can also be connected to the third communication network 44 via the communication interface 58b. The third communication network 44 is an intra-office LAN such as Ethernet (registered trademark), for example. Using the computer terminal 60 connected to the third communication network 44, the database 51a can be updated offline with respect to the Internet. Needless to say, the database 51a can be updated using the failure estimation device 70 or other computer terminal connected to the second communication network 42.

  The CPU 53 of the failure estimation database device 50 is connected to the input interface 54, the output interface 56, the communication interfaces 58a and 58b, and the storage unit 59, respectively. These may be individually connected to the CPU 53 or may be connected via a bus installed inside. For example, the CPU 53 loads a program from the storage unit 59 and executes each step of the program. The input interface 54, the output interface 56, the communication interfaces 58a and 58b, and the storage unit 59 are appropriately controlled according to the steps of the program. Note that the program may be recorded in a storage medium and installed in the failure estimation database device 50, or connected to another server or the like via a communication line and operated by cloud computing that operates on the other server or the like. You may make it operate.

  The input interface 54 is connected to the input unit 55. The input unit 55 includes input devices such as a keyboard, a mouse, and a scanner, for example. Data input from the input unit 55 is transmitted to the CPU 53 via the input interface 54.

  The output interface 56 is connected to the output unit 57. The output unit 57 includes an output device such as a monitor or a printer. In accordance with a command from the CPU 53, appropriate data is output to the output unit 57 via the output interface 56.

  The communication interface 58 a is connected to the third communication network 44. The third communication network 44 is, for example, an intra-office LAN based on Ethernet (registered trademark). The failure estimation database device 50 can be connected to another computer terminal 60 installed in the office via the third communication network 40.

  The communication interface 58b is connected to the second communication network 42. The second communication network 42 is, for example, the Internet. The failure estimation database device 50 can be connected to the failure estimation device 10 via the second communication network 42. The failure estimation database device 50 can also be connected to another failure estimation device 70 via the second communication network 42.

  The failure estimation database device 50 receives, via the second communication network 42, energization time data and environmental element data of the modules 21a to 21d of the PLC 20 collected by the failure estimation device 10. A plurality of failure estimation devices 10 are connected to the second communication network 42, and energization time data and environmental element data of many modules are collected. The energization time data and environmental element data for each module of different models out of many modules are collected, and the energization time data and environmental element data of modules of the same model that are installed in different environments Collected. Also, energization time data and environmental element data are collected for modules of the same model that are installed in the same environment, that is, when a plurality of the same modules are installed in the same environment.

  The database update unit 51 of the failure estimation database device 50 is loaded with a database 51a including environmental element data. The database 51a of the database update unit 51 is updated in a timely manner with the collected environmental element data.

The operation of the failure estimation database device 50 of this embodiment will be described with reference to a flowchart.
FIG. 8 is a flowchart for explaining an example of the operation of the failure estimation database device 50.

  In step S <b> 20, the database update unit 51 performs a reception process for receiving the environmental element data of each module in accordance with the transmission request from each failure estimation apparatus 10. As described above, the failure estimation device 10 collects the energization time data and the environmental element data for each module at each specified time T2, and stores the data for the failure estimation database device 50 at each specified time T1. To send. The failure estimation database device 50 performs reception processing in response to a transmission request from the failure estimation device 10.

  In step S21, the database update unit 51 updates the accumulated energization time data associated with the module in the database 51a using the received accumulated energization time data.

  In step S <b> 22, the database update unit 51 acquires the environmental evaluation threshold values 0 to 5 (FIG. 3) from the received environmental element data from each sensor using the environmental evaluation threshold table 200. The frequency data corresponding to each environmental evaluation threshold level in the database 51a is updated.

  When the failed module is specified, it is input in step S21 or step S22 that the failed module data has a failure. This data may be input manually from the failure estimation apparatus 10 using a keyboard or the like, or may be performed using the keyboard of the failure estimation database apparatus 50 or the like. You may input using another computer terminal via the communication networks 42 and 44. FIG.

  In step S23, the database update unit 51 uses the threshold level frequency data to calculate an environmental element failure contribution rate R (i), which is a ratio of each environmental element i contributing to the failure of the module. The environmental element failure contribution rate R (i) is calculated by the following equation (4).

  Here, i is the number of the environmental element. N is the total number of environmental elements to consider. M is the total number of module failure data. count (l, i, e) is the frequency at which the environmental element i becomes the environmental evaluation threshold level e (i) in the failure data l.

  In step S24, the database update unit 51 updates the environmental evaluation weighting table 300 based on the environmental element failure contribution rate R (i). When there is one faulty module for one module, the R (i) of that module is set as the weight value w (i). Further, when a plurality of failure modules exist for the same type of module, the average value of R (i) of each failure module is set as the weight value w (i). For example, for environmental element 1, w (1) = 0.25 before updating the database is calculated as R (1) average value R (1) av = 0.275 after updating the database. In this case, the weight after the database update is w (1) = 0.275. The database update unit 51 inputs the value of R (i) or R (i) av calculated in step S23 to the weight value input unit 303 of the environment evaluation weighting table 300.

  In step S25, the database update unit 51 performs database update completion processing. After the database update completion process, the updated database can be used. If the database is accessed from the failure estimation apparatus 10 before the database update completion processing, the database before update is used.

  In this way, the failure estimation database device 50 can update the database 51a sequentially by the database update unit 51, and update the weight value of the environmental evaluation weighting table 300 in association with the actual failure and its factor. . Therefore, by using the weight value w (i) of the database 51a, it is possible to estimate the possibility of failure for each module by reflecting the actual condition. Further, the weight value w (i) can be set for each module model name, for example. Since an appropriate weight value w (i) can be set according to the model name of the module, the failure estimation device 10 can be used to better reflect the degree of deterioration between modules with different members and parts. To support the estimation of deterioration.

FIG. 9 is a conceptual diagram showing an example of an environmental evaluation threshold level frequency table 500 which is a part of the database 51a.
As shown in FIG. 9, the environmental evaluation threshold level frequency table 500 includes a device name input unit 501, a failure data number input unit 502, an installation location data input unit 503, a hardware version input unit 504, A failure cause input unit 505, an accumulated energization time input unit 506, an environmental evaluation threshold frequency input unit 507, and a failure contribution rate display unit 508 are included.

  An arbitrary name such as a module model name or product name is input to the device name input unit 501. An arbitrary number is input to the failure data number input unit 502 in order to identify a module for which a failure has been identified from other failure modules. The failure data numbers may be inputted by sequentially assigning numbers by the database updating unit 51 when it is designated that there is a failure. The installation location data input unit 503 receives a plant name, process name, and the like where each module is actually installed. If the installation environment is different even for the same module, the environmental conditions are different, and installation location data is input to identify them. The hardware version input unit 504 receives the hardware version of the module installed at the installation location. The failure cause input unit 505 receives the failure cause of the module for which the failure is specified. The accumulated energization time data of the modules collected by the failure estimation apparatus 10 is input to the accumulated energization time input unit 506. The frequency value for each environmental evaluation threshold for all environmental elements is input to the environmental evaluation threshold frequency input unit 507. The failure contribution rate display unit 508 displays the value of R (i) calculated based on the frequency data for each environmental evaluation threshold level.

  For example, in FIG. 9, environmental elements 1 to 5 correspond to environmental elements 1 to 5 in FIGS. 3 and 4, respectively. That is, the environmental element 1 is the internal temperature Ta (° C.), the environmental element 2 is the internal humidity RH (%), the environmental element 3 is the power supply noise level Vn (dB), and the environmental element 4 Is a power supply voltage fluctuation value ΔVin (reference value ±%), and the environmental element 5 is a consumption current fluctuation value ΔIcc (rated value ±%).

  From the data input to the device name input unit 501 to the cumulative energization time input unit 506, it is indicated that the module A installed in the # 1 line of the A company a factory has failed with an accumulated energization time of 175256 hours. Further, from the data input to the environmental evaluation threshold frequency input unit 507, this module A has the environmental element 1, that is, the frequency of the environmental evaluation threshold level of the panel temperature Ta which is large is the other environmental element. It is shown to be higher than 2-5. The above-described calculation of R (i) shows that the environmental element 1 (in-panel temperature) is the highest at 98.5% with respect to the ratio of the environmental element contributing to the failure of this module. From the data displayed in the failure contribution rate display unit 508, for this module A, the average value of the failure contribution rate R (1) for the environmental element 1 is 50.2%, and the weight value w (1 ) Is 0.502. Similarly, for each module, the average value of the failure contribution rate R (i) is set to the weight value w (i), and the new weight value w (i) is input to the weight value input unit 303 of the environment evaluation weighting table 300. Entered.

  As described above, the failure estimation database device 50 can acquire the actual state of the failure for each module and reflect it, so that the failure estimation device 10 can assist in estimating the failure more accurately.

  If the association between the weight value w (i) and the environmental element is set for each module model name, it is more accurate in accordance with the actual situation for each module model name such as a member or part to be adopted. It is possible to provide a database 51a capable of performing failure estimation.

  Further, for example, since the environmental condition weak for the module is found from the display of the failure contribution rate display unit 508, it is possible to easily take measures for improving the quality of the module. Furthermore, by adding the module for which improvement measures have been taken to the database by changing the hardware version, the operation results can be displayed as the results before and after the measures, and the effect of the measures can be easily confirmed.

  As mentioned above, although some embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the scope of the invention described in the claims and the equivalents thereof. Further, the above-described embodiments can be implemented in combination with each other.

  DESCRIPTION OF SYMBOLS 1 Information collection part, 2 Information analysis part, 3,53 CPU, 4,54 Input interface, 5,55 Input part, 6,56 Output interface, 7,57 Output part, 8a, 8b, 58a, 58b Communication interface, 9 , 59 storage unit, 10, 70 failure estimation device, 20 programmable controller (PLC), 21a-21d module, 22a-22d communication interface, 23a-23d display unit, 24a-24d storage unit, 25a-25d energization time output unit, 30 sensor module, 31a to 31e sensor, 32 communication interface, 40, 42, 44 communication network, 50 failure estimation database device, 51 database update unit, 51a database, 60 computer terminal, 100 failure estimation system, 200 for environment evaluation Threshold table 201, 301 Environmental element number input section 202, 302 Environmental element name input section 203 Threshold classification input section 204 Environmental evaluation threshold level classification display section 300 Environmental evaluation weighting table 303 Weight Value Input Unit, 400 Degradation Point Display Table, 401 Target Module Display Unit, 402 Cumulative Energization Time Degradation Point Display Unit, 403 Failure Possibility Display Unit, 500 Environmental Evaluation Threshold Level Frequency Table, 501 Device Name Input Unit , 502 Failure data number input unit, 503 Installation location data input unit, 504 Hardware version input unit, 505 Failure cause input unit, 506 Cumulative energization time input unit, 507 Threshold value input unit for environmental evaluation, 508 Failure contribution rate Display section

Claims (12)

A failure estimation device that estimates the possibility of failure for each module of a programmable controller,
From the module, an information collecting unit for collecting energization time data for each module, environmental condition data of the environment in which the module is installed, and failure presence / absence data of the module;
An information analysis unit that reads a database including environmental coefficient data representing the degree of deterioration of the module with respect to the environmental condition, and calculates the possibility of failure for each module;
With
The database is collected from a plurality of modules included in a plurality of programmable controllers including the programmable controller, and is based on the energization time data, the environmental coefficient data, and the failure presence / absence data associated with each of the plurality of modules. Failure estimation device to be updated.   The environmental coefficient data is a coefficient related to a threshold value set for each of the environmental conditions, and is an environmental evaluation threshold level data represented by a coefficient for accelerating the deterioration of the module. The failure estimation apparatus according to claim 1, further comprising: environmental evaluation weight value data represented by a coefficient related to the degree of contribution of module deterioration.   The weight value data for environmental evaluation is updated based on the energization time data, the environmental evaluation threshold level data, and the failure presence / absence data associated with each of the plurality of modules. Failure estimation device.   The failure estimation apparatus according to claim 1, wherein the information analysis unit reads the database through a communication line. A failure estimation database device that assists in estimating the possibility of failure of each of a plurality of modules included in a plurality of programmable controllers,
Energization time data of each of the plurality of modules, environmental condition data in which each of the plurality of modules is installed, environmental coefficient data indicating the degree of deterioration of the module with respect to the environmental conditions, and presence / absence of failure of each of the plurality of modules A database update unit that updates a database including data,
The database update unit is a failure estimation database device that updates the database based on the energization time data, the environmental coefficient data, and the failure presence / absence data associated with each of the plurality of modules.   The environmental coefficient data is a coefficient related to a threshold value set for each of the environmental conditions, and is an environmental evaluation threshold level data represented by a coefficient for accelerating the deterioration of the module. 6. The failure estimation database device according to claim 5, further comprising: environmental evaluation weight value data represented by a coefficient related to the degree of contribution of module degradation.   The database update unit updates the environmental evaluation weight value data based on the energization time data, the environmental evaluation threshold level data, and the failure presence / absence data associated with each of the plurality of modules. Item 7. The failure estimation database device according to Item 6. A failure estimation program stored in a memory and sequentially executed by a processor for estimating the possibility of failure for each module of a programmable controller,
Collecting from the module energization time data for each module, environmental condition data of the environment in which the module is installed, and failure presence / absence data of the module;
Reading environmental coefficient data representing the degree of degradation of the module with respect to the environmental conditions from a database;
Calculating the possibility of failure for each module based on the energization time data and the environmental coefficient data;
Have
The database is collected from a plurality of modules included in a plurality of programmable controllers including the programmable controller, and is based on the energization time data, the environmental coefficient data, and the failure presence / absence data associated with each of the plurality of modules. Failure estimation program updated. A failure estimation database program stored in a memory and sequentially executed by a processor for supporting estimation of a possibility of failure of each of a plurality of modules included in a plurality of programmable controllers,
Energization time data of each of the plurality of modules, environmental condition data in which each of the plurality of modules is installed, environmental coefficient data indicating the degree of deterioration of the module with respect to the environmental conditions, and presence / absence of failure of each of the plurality of modules Storing a database containing data;
Updating the database;
Have
In the step of updating the database, a failure estimation database program that updates the database based on the energization time data, the environmental coefficient data, and the failure presence / absence data.   A computer-readable storage medium in which the failure estimation program according to claim 8 is recorded.   A computer-readable storage medium storing the failure estimation database program according to claim 9. A plurality of failure estimation devices for estimating the possibility of failure for each module of the programmable controller;
A failure estimation database device that supports estimation of the possibility of failure for each module;
A communication line connecting the plurality of failure estimation devices and the failure estimation database device;
With
The failure estimation apparatus includes, from the module, an energization time data for each module, environmental condition data of an environment in which the module is installed, and an information collection unit that collects failure presence / absence data of the module, and a module for the environmental condition A storage unit that stores a database including environmental coefficient data representing the degree of deterioration; and an information analysis unit that calculates the possibility of failure for each module based on the energization time data and the environmental element data. ,
The failure estimation database device includes energization time data of each of the plurality of modules, environmental condition data in which each of the plurality of modules is installed, the environmental coefficient data, and failure presence / absence data of each of the plurality of modules. A storage unit for storing the database, and a database update unit for updating the database,
The database update unit is a failure estimation system that updates the database based on the energization time data, the environmental coefficient data, and the failure presence / absence data.

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