Diagnostic device, diagnostic method, and diagnostic program

Abstract

A diagnostic apparatus includes a diagnostic unit that diagnoses a database based on managing an operation history, a fault factor, and a fault countermeasure of a reference field device in an associated manner, and identifies a fault factor and a fault countermeasure of a diagnosis target field device based on the operation history of the diagnosis target field device.

Description

Technical Field

[0001] This invention relates to diagnostic devices, diagnostic methods, and diagnostic procedures. Background Technology

[0002] As is well known, field instruments perform operations for setting and adjusting parameters, as well as operations for recording operation history (see, for example, NPL 1).

[0003] Reference List

[0004] Patent documents

[0005] NPL1: Japanese Patent Publication No. 2005-70936 Summary of the Invention

[0006] Technical issues

[0007] When a field instrument malfunctions, it is necessary to identify the cause of the failure and develop countermeasures. Typically, this involves engineers with specialized knowledge performing reproduction tests and data analysis based on past failure cases. Because this process is time-consuming, it presents a challenge in implementing rapid countermeasures.

[0008] One aspect of this invention provides a rapid fault response strategy.

[0009] Solution to the problem

[0010] According to one aspect of this disclosure, a diagnostic apparatus includes: a diagnostic unit that identifies fault factors and fault countermeasures of a target field instrument based on a diagnostic database and based on the operating history of the target field instrument, wherein the diagnostic database manages the operating history, fault factors, and fault countermeasures of a reference field instrument in an associated manner.

[0011] According to one aspect of this disclosure, a diagnostic method includes: identifying fault factors and fault countermeasures of the target field instrument based on a diagnostic database and based on the operating history of the target field instrument, wherein the diagnostic database manages the operating history, fault factors, and fault countermeasures of the field instrument in a correlated manner.

[0012] According to one aspect of this disclosure, a diagnostic procedure causes a computer to perform processing, the processing including: identifying fault factors and fault countermeasures of the target field instrument based on a diagnostic database and based on the operating history of the target field instrument, wherein the diagnostic database manages the operating history, fault factors, and fault countermeasures of the reference field instrument in a correlated manner.

[0013] Beneficial effects of the invention

[0014] According to the present invention, rapid fault response measures can be taken. Attached Figure Description

[0015] Figure 1 This is a schematic diagram illustrating the configuration of a diagnostic system according to an embodiment.

[0016] Figure 2 This is a schematic diagram illustrating an example of a diagnostic database.

[0017] Figure 3 This is a schematic diagram illustrating an example of data from a field instrument used to diagnose a target.

[0018] Figure 4 This is a schematic diagram illustrating an example of data from a field instrument used to diagnose a target.

[0019] Figure 5 This is a flowchart illustrating an example of a process (diagnostic method) performed in relation to a diagnosis.

[0020] Figure 6 This is a schematic diagram illustrating an example of a hardware configuration. Detailed Implementation

[0021] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Identical components are indicated by the same reference numerals, and repeated descriptions will be omitted.

[0022] Figure 1 This is a schematic diagram illustrating the configuration of a diagnostic system according to an embodiment. The diagnostic system 100 includes a field instrument 1, an external circuit 2, a portable operating device 3, a management device 4, and a diagnostic device 5.

[0023] Field instrument 1 is a measuring instrument installed and used within a field location, such as a factory or manufacturing plant; more specifically, it is a transmitter that sends signals indicating measurement results. Examples of transmitters include pressure transmitters, temperature transmitters, and flow transmitters. Pressure can be interpreted to include the meaning of differential pressure, and a pressure transmitter can be a differential pressure transmitter. Figure 1 The field instrument 1 shown as an example is a two-wire transmitter and is used by connecting to an external circuit 2.

[0024] There are multiple field instruments 1, and Figure 1 In the example shown, three field instruments 1 are illustrated. To distinguish each field instrument 1, each individual field instrument 1 is referred to as field instrument 1-1, field instrument 1-2, and field instrument 1-3. In the following description, unless otherwise specified, field instruments 1-1, 1-2, and 1-3 are simply referred to as field instrument 1.

[0025] The field instrument 1 includes a sensor 11, an arithmetic calculation and operation management unit 12, a DA converter 13, an output circuit 14, a communication IF 15, and an operation switch 16.

[0026] Sensor 11 outputs a sensor value. The sensor value indicates the voltage, current, or other value of the physical quantity (pressure, temperature, flow rate, etc.) being measured by field instrument 1. If field instrument 1 is a pressure transmitter, sensor 11 is a pressure sensor, and more specifically, a pressure-bearing unit (e.g., a diaphragm unit). If field instrument 1 is a temperature transmitter, a temperature sensor corresponds to sensor 11, and if field instrument 1 is a flow transmitter, a flow sensor corresponds to sensor 11.

[0027] The arithmetic calculation and operation management unit 12 acquires the sensor values ​​already output by the sensor 11. Sensor values ​​can be acquired periodically, or at any specified time interval. Figure 1 In the example shown, the arithmetic calculation and operation management unit 12 consists of a microprocessor 121 and a memory 123. Some processes performed by the microprocessor 121 will be described.

[0028] Microprocessor 121 performs arithmetic calculations (calculations) to convert sensor values ​​into measured values. The measured values ​​are physical quantities that are measured, such as pressure values, differential pressure values, temperature values, flow rates, etc. There are no particular limitations on the method used to convert sensor values ​​into measured values; however, for example, an algorithm can be used to calculate the measured values ​​based on the sensor values, or a table in which sensor values ​​and measured values ​​are associated can be referenced. Microprocessor 121 generates a digital signal indicating the measured values ​​obtained through arithmetic calculations, and then outputs the generated measured values ​​to DA converter 13.

[0029] A correction can be added to the arithmetic calculations of the measured values ​​obtained by the microprocessor 121 described above. An example of correction is zeroing, where the measured values ​​obtained through arithmetic calculations are corrected so that the measured values ​​of the sensor 11 included in the field instrument 1 become zero when there is no input. The correction amount used to set the measured value to zero is also called the zeroing amount. The required zeroing amount may change depending on the operating time of the field instrument 1. For example, as the operating time of the field instrument 1 increases, the required zeroing amount also increases.

[0030] The microprocessor 121 performs self-diagnosis on the field instrument 1; more specifically, the microprocessor 121 diagnoses whether the state (instrument state) of the field instrument 1 is normal or abnormal. For example, if the sensor value or measured value is within a predetermined range (within the normal range), the microprocessor 121 diagnoses the state of the field instrument 1 as normal; if the sensor value or measured value is outside the predetermined range (outside the normal range), the microprocessor 121 diagnoses the state of the field instrument 1 as abnormal.

[0031] The microprocessor 121 manages the operations performed by the field instrument 1. The operations performed by the field instrument 1 include adjustments to the field instrument 1. These adjustments are made by setting or changing parameters that define, for example, the operational tasks performed by the field instrument 1. An example of a specific adjustment is the zeroing described above. As will be described later, the operations of the field instrument 1 are performed using the operating switch 16, the portable operating device 3, or the management device 4.

[0032] The microprocessor 121 manages the operations actually performed on the field instrument 1. The management-related function block provided by the microprocessor 121 is called the operation detection unit 122 and is shown.

[0033] The operation detection unit 122 detects the operations performed on the field instrument 1 and stores the operation history in the memory 123 as operation history 126. If a stored operation history 126 exists, it can be updated. Operation history 126 contains data related to operation time, operation content, etc. Operation content includes operation quantities, such as the zeroing quantity mentioned above. Furthermore, in this embodiment, it is assumed that the operation time of the field instrument 1 is also included in the operation history 126. The operation time indicates, for example, the time (length of the time period) between the point when the operation of the field instrument 1 began and the point when the operation history 126 was recorded.

[0034] The memory 123 stores data used by the arithmetic calculation and operation management unit 12. Examples of data stored in the memory 123 include basic data 124, parameters 125, and operation history 126. The operation history 126 has already been described above, so the basic data 124 and parameters 125 will be described next.

[0035] Basic data 124 is inherent data for field instrument 1. Examples of basic data 124 include instrument ID (identifier), instrument type, instrument label name, and supplier name. The instrument ID is an identifier used to uniquely identify field instrument 1. The instrument type indicates the type of field instrument 1, including, for example, a pressure transmitter, temperature transmitter, flow transmitter, etc. The instrument label is data used to identify field instrument 1 and is configured to allow operators to easily read the data. The supplier name indicates the supplier of field instrument 1.

[0036] Parameter 125 is set in field instrument 1 and defines, for example, the operation performed by field instrument 1. Examples of parameter 125 include: the period of arithmetic calculation of the measured value (measurement period), the display unit of the measured value, and the instrument status of field instrument 1 obtained through self-diagnosis.

[0037] The DA converter 13 converts the digital signal (signal indicating the measurement value) received from the microprocessor 121 into an analog signal and outputs the converted signal to the output circuit 14.

[0038] Output circuit 14 is connected between external circuit 2 and external circuit 2. Output circuit 14 converts the analog signal received from DA converter 13 into a current signal and performs control to make the current signal flow through external circuit 2 and output circuit 14. The current signal appears in external circuit 2 as a current signal varying from 4mA to 20mA, depending on the signal indicating the measured value (i.e., according to the amplitude of the measured value).

[0039] The external circuit 2 will now be described. The external circuit 2 is connected to the associated field instrument 1. Multiple external circuits 2 exist, each associated with a corresponding field instrument 1, and... Figure 1 The diagram illustrates, by way of example, external circuits 2-1 to 2-3, which are associated with field instruments 1-1 to 1-3 respectively. In the following description, unless otherwise specified, external circuits 2-1 to 2-3 will be referred to simply as external circuit 2.

[0040] External circuit 2 includes transmission lines 21, a DC power supply 22, and a resistor 23. Transmission lines 21 are a pair of transmission lines 21 connected to the output circuit 14 included in field instrument 1. The DC power supply 22 and the resistor 23 are connected in series between the pair of transmission lines 21.

[0041] If the aforementioned current signal flows through external circuit 2, a voltage (potential difference) is generated between the two ends of resistor 23, that is, between the pair of transmission lines 21, with an amplitude consistent with the amplitude of the current signal. By detecting this voltage, the measurement value already obtained by field instrument 1 can be acquired. Thus, the measurement value obtained by field instrument 1 is transmitted from field instrument 1 to the outside.

[0042] Here, we return to the field instrument 1 for explanation. Communication IF 15 is a communication interface connected to the transmission line 21 included in the external circuit 2. By using the transmission line 21 included in the external circuit 2 as a communication line, communication IF 15 communicates with a device located outside the field instrument 1 (i.e., the portable operating device 3 and the management device 4 in this example).

[0043] The operating switch 16 is used to operate the field instrument 1. For example, the operating switch 16 includes various types of switches that respond to operations performed on the field instrument 1. As a result of the operator changing the switch, the associated operation is performed on the field instrument 1.

[0044] The portable operating device 3 is also used to operate the field instrument 1. When using the portable operating device 3, it is connected to the transmission line 21 included in the external circuit 2 and communicates with the communication IF 15 included in the field instrument 1. For example, the portable operating device 3 sends an operation request (a command, etc., indicating an operation) to the communication IF 15 included in the field instrument 1. In the field instrument 1, the microprocessor 121 operates the field instrument 1 according to the operation request received by the communication IF 15.

[0045] The management device 4 is used to manage the field instrument 1, and the management of the field instrument 1 also includes the operation of the field instrument 1. The management device 4 includes a field instrument communication unit 41, an instrument data management unit 42, an instrument data storage unit 43, a user interface unit 44, and a written work report generation unit 45.

[0046] The field instrument communication unit 41 is connected to the transmission line 21 included in each of the plurality of external circuits 2, and communicates with the communication IF 15 included in each of the plurality of field instruments 1 by using the transmission line 21 as a communication line.

[0047] The instrument data management unit 42 performs overall control of the management device 4 by controlling devices other than the management device 4. For example, the instrument data management unit 42 acquires (collects) data related to each field instrument 1 by controlling the field instrument communication unit 41. Examples of acquired data include basic data 124, parameters 125, operation history 126, etc., stored in the memory 123 included in each field instrument 1. Furthermore, the instrument data management unit 42 operates each field instrument 1 by controlling the field instrument communication unit 41. Similar to the portable operating device 3, operations can be performed by sending an operation request.

[0048] The instrument data storage unit 43 is a database, which is arranged with data related to the field instrument 1 obtained by the instrument data management unit 42, and stores data as instrument data 431 therein. Figure 1 In the example shown, instrument data 431 associated with each field instrument 1 is arranged. Each piece of instrument data 431 is associated with basic data 124, parameters 125, operation history 126, and supplementary data 127 related to the field instrument 1. In addition, the supplementary data 127 is data (memos, images, etc.) arbitrarily generated by the operator regarding the associated field instrument 1 as additional data.

[0049] User interface unit 44 displays instrument data 431 and receives operations performed by each field instrument 1. Figure 1 In the example shown, the user interface unit 44 includes a display setting unit 441 for connecting instruments and a display setting unit 442 for saving instrument data. The display setting unit 441 for connecting instruments displays data acquired from the field instrument 1 that is currently being connected (during communication establishment) and receives operations performed by the connected field instrument 1. The display setting unit 442 for saving instrument data displays instrument data 431 related to any field instrument 1 stored in the instrument data saving unit 43, and receives operations performed by any field instrument 1.

[0050] The written work report generation unit 45 generates a written work report, which describes at least some instrument data 431 according to a predetermined format (template). For example, by generating each written work report about the operation performed on the field instrument 1 before and after, data related to the operation before and after the operation can be retained in the form of written reports.

[0051] Before describing the diagnostic device 5, problems in conventional technology will be described. There may be situations where the field instrument 1 malfunctions (becomes in an abnormal state). Conventionally, engineers with specialized knowledge perform diagnostic tasks to identify the cause of the malfunction or to identify appropriate countermeasures. Specifically, engineers use a portable operating device 3 or a management device 4 to acquire data related to the operating history 126 of the malfunctioning field instrument 1, and perform diagnostic tasks such as reproduction testing and data analysis by referring to cases of other field instruments 1 that have malfunctioned in the past. After identifying the cause of the malfunction or the countermeasures through such diagnostic tasks, the countermeasures are provided to the user of the field instrument 1. Diagnostic tasks require a significant amount of time, thus making it difficult to implement rapid countermeasures.

[0052] According to this embodiment, as described below, the diagnostic work (including work for identifying fault factors and fault countermeasures) for the field instrument 1 is automated by the diagnostic device 5, thus enabling rapid fault countermeasures.

[0053] Specifically, the diagnostic device 5 diagnoses one of the multiple field instruments 1 that serves as the diagnostic target. The field instrument 1 that serves as the diagnostic target is also referred to as the "diagnostic target field instrument." Furthermore, in Figure 1In the example shown, the diagnostic device 5 is configured to communicate with the management device 4 via network N. The diagnostic device 5 can be a server device (cloud device) located away from the field instrument 1 and the management device 4, or it can be an on-premises device located near the field instrument 1 and the management device 4. The diagnostic device 5 includes a storage unit 51, a diagnostic unit 52, and an output unit 53.

[0054] The storage unit 51 stores data used in the diagnostic device 5. Examples of data stored in the storage unit 51 include the diagnostic database 511 and the diagnostic program 512.

[0055] The diagnostic database 511 includes data related to field instruments 1 that have experienced past failures, identified failure factors, and countermeasures. Such field instruments 1 are also referred to as "reference field instruments." Figure 2 Describe the diagnostic database 511.

[0056] Figure 2 This is a schematic diagram illustrating an example of a diagnostic database. The diagnostic database 511 manages basic data 124, parameters 125, fault factors, fault countermeasures, and operating history 126 related to the reference field instruments in an associated manner. In this example, field instruments 1-1 and 1-2 are "reference field instruments," and hereinafter, field instruments 1-1 and 1-2 may also be referred to as reference field instruments 1-1 and 1-2.

[0057] A data ID is an identifier used to uniquely identify data. Figure 2 The example shown here contains 14 data entries associated with data IDs 1 through 14.

[0058] Basic data 124 serves as instrument management data to uniquely identify field instrument 1. For example, the instrument ID or combination of instrument type and instrument tag name included in basic data 124 can be instrument management data. Figure 1 In the diagram, the instrument management data for reference field instrument 1-1 is schematically shown as instrument management data A000001. The instrument management data for reference field instrument 1-2 is schematically shown as instrument management data A000002.

[0059] More specifically, parameter 125 represents the instrument status. In this example, among the data IDs indicated by 1 to 5, the instrument status of reference field instrument 1-1 is normal, while in the data ID indicated by 6, the instrument status of reference field instrument 1-1 is abnormal. Among the data IDs indicated by 7 to 13, the instrument status of reference field instrument 1-2 is normal, while in the data ID indicated by 14, the instrument status of reference field instrument 1-2 is abnormal.

[0060] A failure factor is a factor that has caused a failure in each of reference field instruments 1-1 and 1-2; in other words, it is a factor that causes the abnormal state of reference field instruments 1-1 and 1-2. For a single abnormal state, there may be multiple failure factors, which are described as failure factor 1, failure factor 2, etc.

[0061] In this embodiment, in the data ID indicated by 6, fault factor 1 is indicated as hydrogen permeation. Hydrogen permeation is a permeation phenomenon that occurs in the pressure-bearing unit (e.g., a metal diaphragm unit) included in a pressure transmitter, where hydrogen ions permeate into the enclosed liquid. This phenomenon is caused by hydrogen contained in the fluid and leads to measurement errors.

[0062] In the data ID indicated by 14, fault factor 1 is indicated as operational error. Operational error is an error that occurs when the operator performs operation on field instrument 1. Examples of operational errors include incorrect adjustment sequence of reference field instruments 1-2, excessive pressure being applied, etc.

[0063] Troubleshooting measures are countermeasures performed on reference field instruments 1-1 and 1-2; in other words, they are measures to restore reference field instruments 1-1 and 1-2 to their normal state. Multiple troubleshooting measures can be performed on a single abnormal state, and each troubleshooting measure can be independently described as Troubleshooting Measures 1, Troubleshooting Measures 2, etc.

[0064] In this example, in the data ID indicated by 6, fault response 1 is indicated as instrument replacement. As its name suggests, instrument replacement indicates that field instrument 1-1 has been replaced.

[0065] In the data ID indicated by 14, fault response 1 is indicated as instrument replacement, and fault response 2 is indicated as operation training. The operation training instruction indicates that the operator who performed the incorrect operation has received operation-related education (training) to prevent the recurrence of faults caused by the same operational error.

[0066] Here, Operation History 126 specifically refers to operation time and operation quantity. The operation time of Reference Field Instrument 1-1 increases sequentially according to data IDs 1 to 6. The operation time of Reference Field Instrument 1-2 increases sequentially according to data IDs 7 to 14. For example, the operation quantity is the zeroing amount, as described above, and the numerical value of the operation quantity is schematically indicated. In this example, the operation quantity of Reference Field Instrument 1-1 gradually increases as the operation time increases. Even if the operation time increases, the operation quantity of Reference Field Instrument 1-2 will not change, but an operation error can cause the operation quantity of Reference Field Instrument 1-2 to increase sharply.

[0067] For example, the diagnostic database 511 is pre-generated and stored in storage unit 51. There is no particular restriction on the specific order of the processes used to generate the diagnostic database 511; for example, there may be tasks performed by operators, engineers, etc. of the field instrument 1 between these processes.

[0068] Here, we will return to the reference. Figure 1 The diagnostic program 512 stored in storage unit 51 is a program (software, application program) that enables the computer to operate as a diagnostic device 5.

[0069] The diagnostic unit 52 diagnoses the target field instrument based on the diagnostic database 511 and data related to the target field instrument. It will also refer to... Figure 3 Describe data related to the field instruments used for diagnosis.

[0070] Figure 3 This is a schematic diagram illustrating an example of data related to a diagnostic target field instrument. This data correlates the data ID, basic data 124 (more specifically, instrument management data), parameters 125 (more specifically, instrument status), and operation history 126 (more specifically, operation time, operation quantity) of the diagnostic target field instrument with each other. In this example, field instrument 1-3 is the "diagnostic target field instrument," and in the following description, field instrument 1-3 will also be referred to as diagnostic target field instrument 1-3. The instrument status of diagnostic target field instrument 1-3 is normal in data IDs indicated by 101 to 105, and abnormal in data ID indicated by 106.

[0071] For example, data related to the above-mentioned diagnostic target field instruments 1-3 can be obtained from the management device 4.

[0072] Here, we will return to the reference. Figure 1 The diagnostic unit 52 performs diagnostics on the target field instruments 1-3 based on the diagnostic database 511 and data related to the target field instruments 1-3 (operation history 126, etc.). The diagnosis includes the identification of fault factors and countermeasures for the target field instruments 1-3.

[0073] First, the diagnostic unit 52 searches the diagnostic database 511 for reference field instruments (e.g., reference field instrument 1-1 or reference field instrument 1-2) that have similar operation history 126 to the target field instrument. Similarity can be interpreted as including the meaning of similarity.

[0074] One example of similarity is the similarity of the changes in operational quantities (e.g., zeroing quantity) over time. In this case, diagnostic unit 52 retrieves a reference field instrument from diagnostic database 511 whose changes in operational quantities over time are similar to those of the target field instruments 1-3.

[0075] For example, diagnostic unit 52 calculates the change in operating quantity over time based on the operating time and operating quantity of the target field instruments 1-3, and generates data on the change in operating quantity indicating the calculation result. This data on the change in operating quantity can also be described as data obtained by differentiating (discretizing and differentiating) the operating quantity relative to the operating time. Similarly, diagnostic unit 52 generates data on the change in operating quantity for each reference field instrument included in the diagnostic database 511 based on its operating time and operating quantity. Diagnostic unit 52 then retrieves reference field instruments from the diagnostic database 511 whose data on the change in operating quantity is similar to the data on the change in operating quantity related to the target field instruments 1-3. Various known methods can be used to determine this similarity.

[0076] The above references Figure 2 and Figure 3 In the described example, the operation history 126 of the target field instrument 1-3 and the operation history 126 of the reference field instrument 1-1 are similar to each other. The diagnostic unit 52 searches the diagnostic database 511 and detects the reference field instrument 1-2. Then, the diagnostic unit 52 identifies the fault factors and fault countermeasures (i.e., hydrogen permeation and instrument replacement) of the reference field instrument 1-1 as the fault factors and fault countermeasures of the target field instrument 1-3.

[0077] In one embodiment, for the target field instruments 1-3 that have not yet failed, the diagnostic unit 52 diagnoses the trend of whether a failure will occur or not. In this case, the diagnostic unit 52 can identify failure factors and countermeasures that may occur in the target field instruments 1-3 in the future. (See reference...) Figure 4 Describe an example.

[0078] Figure 4 This is a schematic diagram illustrating an example of data from a field instrument used to diagnose a target. (With) Figure 3 compared to, Figure 4and Figure 3 The difference is that, Figure 4 Data with a data ID indicated by 106 is not included. The diagnostic target field instruments 1-3 are in normal condition and no malfunction has occurred.

[0079] Even under these circumstances, the operation history 126 of the diagnostic target field instrument 1-3 and the operation history 126 of the reference field instrument 1-1 are similar to each other. Figure 2 This causes the diagnostic unit 52 to search the diagnostic database 511 and detect the reference field instrument 1-1. Then, the diagnostic unit 52 estimates that a fault in the reference field instrument 1-1 (i.e., a fault caused by hydrogen permeation) will occur in the target field instrument 1-3, and identifies this as a fault factor. Furthermore, the fault countermeasure for the reference field instrument 1-1 (i.e., instrument replacement) is identified as a fault countermeasure for the target field instrument 1-3.

[0080] Here, return to the reference. Figure 1 The diagnostic unit 52 generates data indicating the diagnostic results for the target field instruments 1-3. The diagnostic results include the identified operating history 126 (operation time, operation quantity, etc.), fault factors, and fault countermeasures for the target field instruments 1-3. In addition, the diagnostic results may also include basic data 124, parameters 125, and auxiliary data 127 of the target field instruments 1-3.

[0081] Output unit 53 outputs the diagnostic results generated by diagnostic unit 52. For example, output unit 53 consists of a display, a data output port, etc., and displays the diagnostic results and outputs data. As a result of outputting the diagnostic results, the diagnostic results are notified to the relevant personnel, such as the user, operator, engineer, etc. of field instrument 1.

[0082] For example, in the manner described above, the diagnostics of target field instruments 1-3 are performed (including identifying fault factors and countermeasures for target field instruments 1-3), and the diagnostic results are output. The diagnostic device 5 automatically diagnoses the target field instruments 1-3, eliminating the need for engineers with specialized knowledge to always spend time performing tasks such as analysis. Even when the frequency of analysis is reduced, or even when analysis is performed, the analysis time can be shortened. Therefore, rapid fault countermeasures can be taken. When the diagnostic unit 52 diagnoses the trend of whether or not a fault will occur in the target field instruments 1-3 before a fault occurs, its diagnostic results are output, allowing for the prevention of faults in advance.

[0083] The timing of the diagnostics performed by the diagnostic unit 52 is unrestricted. For example, the diagnostic unit 52 can monitor the instrument status of each field instrument 1 by accessing the instrument data 431 included in the instrument data storage unit 43 included in the management device 4, and can identify field instruments 1 with abnormal instrument status (already malfunctioning) as target field instruments for diagnosis. Diagnosis is performed immediately after a fault is detected. When field instruments 1 with normal instrument status (not yet malfunctioning) are selected as targets, appropriate diagnosis can be performed to prevent faults from occurring in advance. Of course, operators, engineers, etc., can also operate the diagnostic device 5 to manually select target field instruments for diagnosis.

[0084] The diagnostic database 511 can also be updated by effectively using the diagnostic results. For example, the diagnostic unit 52 can add previously diagnosed target field instruments 1-3 (i.e., target field instruments 1-3 whose fault factors and countermeasures have been identified) as new reference field instruments to the diagnostic database 511. The specific data to be added is as described above. Figure 2 The data shown is used to improve the accuracy of subsequent diagnostics performed on other target field instruments by accumulating a larger amount of data related to the reference field instrument into the diagnostic database 511.

[0085] Figure 5 This is a flowchart illustrating an example of a process (diagnostic method) performed in relation to a diagnosis. Descriptions overlapping with the above will be omitted as appropriate.

[0086] In step S1, a diagnostic database 511 is prepared. The diagnostic database 511 is stored in a storage unit 51 included in the diagnostic device 5.

[0087] In step S2, the diagnostic unit 52 included in the diagnostic device 5 acquires the operation history of the target field instruments. For example, it acquires the operation history 126 associated with the target field instruments 1-3 and included in the instrument data 431, wherein the instrument data 431 is stored in the instrument data storage unit 43 included in the management device 4. It may also acquire the basic data 124 and parameters 125 of the target field instruments 1-3.

[0088] In step S3, the diagnostic unit 52 included in the diagnostic device 5 searches the diagnostic database 511 for a reference field instrument whose operating history is similar to that of the target field instrument. For example, a reference field instrument 1-1 is detected by searching for a reference field instrument 1-1 whose operating history is similar to the operating history 126 of the target field instrument 1-3.

[0089] In step S4, the diagnostic unit 52 included in the diagnostic device 5 identifies the fault factors and countermeasures of the detected reference field instrument as the fault factors and countermeasures of the target field instrument. For example, the fault factors and countermeasures of the reference field instrument 1-1 (i.e., hydrogen permeation and instrument replacement) are identified as the fault factors and countermeasures of the target field instrument 1-3.

[0090] In step S5, the output unit 53 of the diagnostic device 5 outputs the diagnostic results. The results include the diagnostic results of the fault factors and countermeasures identified in the previous step S4.

[0091] In step S6, the diagnostic unit 52 included in the diagnostic device 5 updates the diagnostic database 511. For example, the diagnostic target field instruments 1-3, whose fault factors and countermeasures have already been identified in the previous step S4, are added to the diagnostic database 511 as new reference field instruments. After that, the process returns to step S2.

[0092] After the processing in step S6 is completed, the process returns to step S2. By repeating the processing from step S2 to step S6, the diagnosis of the target field instrument that actually malfunctions, or even the target field instrument that is likely to malfunction before the malfunction occurs, is appropriately and automatically performed, and then its diagnostic results are obtained.

[0093] <Edit>

[0094] The disclosed technology is not limited to the embodiments described above. For example, the operating quantity is not limited to the zeroing quantity. Any operating quantity that is related to the fault of the field instrument 1 can be used. By accumulating data related to various operating quantities into the diagnostic database 511, a wide variety of faults can be addressed.

[0095] All data related to field instrument 1 (e.g., all data regarding basic data 124, parameters 125, and operating history 126 (and supplementary data 127)) can be stored in the diagnostic database 511. By using past data regarding measurement targets, operating environments, failure cases, and troubleshooting measures related to the model of field instrument 1, this data can be used as a specification factor to recommend to the user upon new purchase. For example, given the possibility of failures caused by hydrogen permeation, it can be recommended to use a pressure transmitter with a gold-coated pressure unit to reduce the likelihood of hydrogen permeation, rather than using a pressure unit (diaphragm unit) coated with a common metal membrane.

[0096] <Example of hardware configuration>

[0097] Figure 6This is a schematic diagram illustrating an example of hardware configuration. Devices such as the computer 9 shown as an example are used as the aforementioned field instrument 1, portable operating device 3, management device 4, or diagnostic device 5. Example hardware configurations of the computer 9 include a communication device 91, a display device 92, a storage device 93, a memory 94, and a processor 95 connected to each other via a bus, etc.

[0098] The communication device 91 is a network interface card or similar device, and is capable of communicating with other devices. For example, the communication device 91 may correspond to the aforementioned communication IF 15, field instrument communication unit 41, etc. The display device 92 may correspond to, for example, the aforementioned output unit 53, etc.

[0099] Various types of data are stored in storage device 93 and memory 94. Specific examples of storage device 93 are hard disk drive (HDD), read-only memory (ROM), random access memory (RAM), etc. Memory 94 may also be part of storage device 93. As data stored in storage device 93, program 931 is an example. Program 931 is a program (software) that enables computer 9 to be used as field instrument 1, portable operating device 3, management device 4, or diagnostic device 5. An example of program 931 is the diagnostic program 512 described above, which enables computer 9 to execute the processing performed by diagnostic unit 52.

[0100] The processor 95 performs various processes. For example, the processor 95 enables the computer 9 to perform various processes that are executed in the field instrument 1, portable operating device 3, management device 4, or diagnostic device 5 by reading (reading out) program 931 from storage device 93 and loading the read out program 931 into memory 94.

[0101] Program 931 can be distributed jointly or separately via a network such as the Internet. Alternatively, program 931 can be executed by storing program 931 jointly or separately on a computer-readable recording medium (such as a hard disk, floppy disk (FD), CD-ROM, magneto-optical disk (MO), digital multifunction disk (DVD), etc.) and by reading program 931 from the recording medium by computer 9.

[0102] For example, the above-described technology is specified below. One of the disclosed technologies is diagnostic device 5. (Refer to the above.) Figures 1 to 4As described above, the diagnostic device 5 includes a diagnostic unit 52 that identifies fault factors and countermeasures for the target field instruments 1-3 based on a diagnostic database 511 and the operating history 126 of the target field instruments 1-3. The diagnostic database 511 manages the operating history 126, fault factors, and countermeasures of reference field instruments 1-1, 1-2, etc., in a correlated manner. According to the diagnostic device 5, the target field instruments 1-3 can be automatically diagnosed by effectively using the diagnostic database 511, including identifying fault factors and countermeasures. Therefore, this enables rapid fault response.

[0103] The diagnostic unit 52 can retrieve the operating history 126 of a reference field instrument 1-1 from the diagnostic database 511, which is similar to the operating history 126 of the target field instrument 1-3. Fault factors and countermeasures (e.g., hydrogen permeation and instrument replacement) already detected through the retrieval and associated with the reference field instrument 1-1 are identified as fault factors and countermeasures for the target field instrument 1-3. The operating history 126 may include operating quantities (e.g., zeroing quantities), and similarity may also include the similarity of changes in operating quantities over time. For example, by effectively using the diagnostic database 511 and the similarity retrieval performed as described above, fault factors and countermeasures for the target field instrument 1-3 can be identified.

[0104] The diagnostic unit 52 can identify potential fault factors and countermeasures that may occur in the target field instruments 1-3 in the future. This allows for the prevention of potential faults in the target field instruments 1-3.

[0105] The diagnostic unit 52 can also add the diagnostic target field instruments 1-3, whose fault factors and countermeasures have been identified, as new reference field instruments to the diagnostic database 511. This allows for the accumulation of a larger amount of data related to the reference field instruments into the diagnostic database 511, and the accumulated data can be used to improve the accuracy of subsequent diagnoses performed on other diagnostic target field instruments.

[0106] The diagnostic device 5 may include an output unit 53, which outputs diagnostic results including the fault factors and countermeasures for the target field instruments 1-3 identified by the diagnostic unit 52. Notifying relevant personnel of the diagnostic results facilitates rapid fault response.

[0107] The above is for reference only. Figures 1 to 5The diagnostic method described above is also one of the disclosed technologies. The diagnostic method includes identifying fault factors and countermeasures for the target field instruments 1-3 based on the diagnostic database 511 and the operating history 126 of the target field instruments 1-3 (steps S2 to S4). As described above, even using this diagnostic method, rapid countermeasures can be taken.

[0108] The above is for reference only. Figures 1 to 6 The diagnostic procedure 512 described above is also one of the disclosed technologies. The diagnostic procedure 512 enables the computer 9 to perform processing (steps S2 to S4) based on the diagnostic database 511 and the operation history 126 of the target field instruments 1-3 to identify fault factors and countermeasures for the target field instruments 1-3. Even using the diagnostic procedure 512, as described above, rapid countermeasures can be taken. A computer-readable recording medium storing the diagnostic procedure 512 is also one of the disclosed technologies.

[0109] The following describes some examples of combinations of the disclosed technical features. (1)

[0111] A diagnostic device includes a diagnostic unit that identifies fault factors and countermeasures of a target field instrument based on a diagnostic database and the operating history of the target field instrument, wherein the diagnostic database manages the operating history, fault factors, and countermeasures of the target field instrument in a correlated manner. (2)

[0113] According to the diagnostic device of (1), wherein,

[0114] The diagnostic unit is configured to:

[0115] Search the diagnostic database for reference field instruments whose operating history is similar to that of the target field instrument.

[0116] The fault factors and countermeasures of the reference field instruments detected by retrieval will be identified as the fault factors and countermeasures of the target field instruments for diagnosis. (3)

[0118] According to the diagnostic device described in (2), wherein,

[0119] Operation history includes operation volume, and

[0120] Similarity includes the similarity of the operation quantities over time. (4)

[0122] According to the diagnostic device described in (3), the operating quantity includes the zeroing quantity. (5)

[0124] The diagnostic device according to any one of (1) to (4) wherein the diagnostic unit identifies fault factors and fault countermeasures related to faults that may occur in the target field instrument in the future. (6)

[0126] According to any one of (1) to (5) of the diagnostic apparatus, wherein the diagnostic unit adds the diagnostic target field instrument for which fault factors and fault countermeasures have been identified to the diagnostic database as a new reference field instrument. (7)

[0128] The diagnostic device according to any one of (1) to (6) further includes an output unit, which outputs diagnostic results including fault factors and fault countermeasures related to the diagnostic target field instrument identified by the diagnostic unit. (8)

[0130] A diagnostic method, comprising:

[0131] The diagnostic database is used to identify fault factors and countermeasures for the target field instrument based on the diagnostic database and the operation history of the target field instrument. The diagnostic database manages the operation history, fault factors and countermeasures of the reference field instrument in an associated manner. (9)

[0133] A diagnostic program that causes a computer to perform a process including the following steps:

[0134] The diagnostic database is used to identify fault factors and countermeasures for the target field instrument based on the diagnostic database and the operation history of the target field instrument. The diagnostic database manages the operation history, fault factors and countermeasures of the reference field instrument in an associated manner.

[0135] Reference Symbol List

[0136] 100 Diagnostic System

[0137] 1. Field Instruments

[0138] 1-1 Reference Field Instruments

[0139] 1-2 Reference Field Instruments

[0140] 1-3 Diagnostic Targets and On-Site Instruments

[0141] 11 Sensors

[0142] 12 Arithmetic Calculation and Operation Management Unit

[0143] 121 microprocessor

[0144] 122 Operation Detection Unit

[0145] 123 Memory

[0146] 124 Basic Data

[0147] 125 parameters

[0148] 126 Operation History

[0149] 127 Supplementary Data

[0150] 13 DA Converters

[0151] 14 Output Circuit

[0152] 15 Communication IF

[0153] 16 Operating switches

[0154] 2. External Circuit

[0155] 21 Transmission Line

[0156] 22 DC power supply

[0157] 23 Resistors

[0158] 3 Portable operating device

[0159] 4. Management device

[0160] 41 Field Instrument Communication Unit

[0161] 42 Instrument Data Management Unit

[0162] 43 Instrument Data Storage Unit

[0163] 431 Instrument Data

[0164] 44 User Interface Unit

[0165] 441 Display and setting unit for connecting instruments

[0166] 442 Display setting unit for saving instrument data

[0167] 45. Written Work Report Generation Unit

[0168] 5. Diagnostic Device

[0169] 51 storage units

[0170] 511 Diagnostic Database

[0171] 512 Diagnostic Procedure

[0172] 52 Diagnostic Units

[0173] 53 Output Unit

[0174] 9. Computers

[0175] 91 Communication devices

[0176] 92 Display devices

[0177] 93 Storage devices

[0178] 931 Program

[0179] 94 Memory

[0180] 95 processor

[0181] N Network

Claims

1. A diagnostic device, comprising: The diagnostic unit identifies fault factors and countermeasures of the target field instrument based on a diagnostic database and the operating history of the target field instrument, wherein the diagnostic database manages the operating history, fault factors, and countermeasures of the reference field instrument in a correlated manner.

2. The diagnostic device according to claim 1, wherein, The diagnostic unit is configured to: Search the diagnostic database for reference field instruments whose operation history is similar to that of the target field instrument. as well as The fault factors and countermeasures of the reference field instruments detected by retrieval are identified as the fault factors and countermeasures of the target field instrument for diagnosis.

3. The diagnostic device according to claim 2, wherein, The operation history includes the operation amount, and The similarity includes the similarity of the operation quantity over time.

4. The diagnostic device of claim 3, wherein, The operational quantities include zeroing quantities.

5. The diagnostic device according to any one of claims 1 to 4, wherein, The diagnostic unit identifies fault factors and countermeasures related to potential future faults in the field instruments of the diagnostic target.

6. The diagnostic device according to any one of claims 1 to 4, wherein, The diagnostic unit adds the identified fault factors and countermeasures of the target field instruments to the diagnostic database as new reference field instruments.

7. The diagnostic device according to any one of claims 1 to 4, further comprising: The output unit outputs diagnostic results including fault factors and countermeasures related to the field instrument of the diagnostic target, as identified by the diagnostic unit.

8. A diagnostic method, comprising: The diagnostic database is used to identify fault factors and countermeasures for the target field instrument based on the diagnostic database and the operating history of the target field instrument. The diagnostic database manages the operating history, fault factors, and countermeasures of the reference field instrument in an associated manner.

9. A diagnostic program that causes a computer to perform the following processes: The diagnostic database is used to identify fault factors and countermeasures for the target field instrument based on the diagnostic database and the operating history of the target field instrument. The diagnostic database manages the operating history, fault factors, and countermeasures of the reference field instrument in an associated manner.

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