Heat source equipment maintenance support system

Abstract

To clearly indicate a basis and an objective index related to the necessity of maintenance and parts replacement, to perform only the necessary maintenance and parts replacement, to reduce costs, to make a user convinced, and to simplify business in a maintenance company.SOLUTION: The heat source facility maintenance support system includes a limit deterioration index determination unit that determines a limit deterioration index that is a limit value of a deterioration index indicating a degree of deterioration of a device or a component constituting the heat source facility according to use state data indicating a use state of the heat source facility, a service life storage unit that stores a service life of the component, a service life upper limit value determination unit that determines a service life upper limit value of the component of the heat source facility based on the service life and the limit deterioration index, and an information generation unit that generates information on a safety degree of the component including the service life upper limit value of the component.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a heat source equipment maintenance support system for managing heat source equipment. [Background technology]

[0002] Air conditioning equipment installed in large facilities such as buildings, and heat source equipment used for process cooling in factories, are composed of multiple devices such as turbo chillers, absorption chiller-heaters, cooling towers, pumps, etc. For this reason, there is a demand for a heat source equipment maintenance support system that can manage the usage status of these multiple devices and enable accurate maintenance, repairs, part replacement, etc. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-231376 Summary of the Invention [Problem to be solved by the invention]

[0004] In conventional heat source equipment management methods, maintenance work is performed from the perspective of time-based maintenance, based on the years of use of the equipment or parts, according to predetermined cycles based on the maintenance cycle in the instruction manual, etc. Furthermore, even for the same years of use, the degree of deterioration of parts varies depending on the equipment's usage and load conditions, so when it is time to recommend maintenance, repair, or part replacement, it may be unclear how much deterioration the parts that are the target of maintenance, etc. are. Even in such cases, when the pre-specified maintenance timing arrives, parts with unknown degrees of deterioration may have to be targeted for replacement, etc.

[0005] Furthermore, because no objective indicators are provided for the degree of deterioration of parts, the basis for recommending maintenance, repairs, or part replacement may not be clearly stated. Users of heat source equipment may find it difficult to accept such recommendations for maintenance, etc., without providing any basis for doing so.

[0006] In view of the above-mentioned problems, the present invention aims to provide a heat source equipment maintenance support system that clearly indicates the basis and objective indicators for the necessity of maintenance, repair, and part replacement, and performs only the necessary maintenance and part replacement, thereby reducing costs, satisfying users, and simplifying the work of maintenance companies. [Means for solving the problem]

[0007] In one aspect, a heat source equipment maintenance support system includes: a limit deterioration index determination unit that determines a limit deterioration index, which is a limit value of a deterioration index indicating the degree of deterioration of a device or part that constitutes the heat source equipment, based on usage data indicating the usage status of the heat source equipment; a useful life storage unit that stores the useful life of the device or part; a use life upper limit value determination unit that determines an upper limit of the use life of the part of the heat source equipment based on the useful life and the limit deterioration index; and an information generation unit that generates information regarding the safety of the device or part, including the upper limit of the use life of the device or part. According to this aspect, part replacement and maintenance proposals can be made taking into account the degree of deterioration of the device or part depending on the usage status and load status of the heat source equipment.

[0008] In one aspect, the service life storage unit is configured to store the service life determined by a service life determination unit that determines the service life for each of the devices or components based on past usage data, or to store a service life that is predetermined for each of the devices or components. According to this aspect, past performance data for the devices or components can be compiled by equipment model or by component, allowing for more accurate calculation of the service life.

[0009] In one aspect, the information generating unit is configured to generate a current deterioration index of the device or the part based on the elapsed time from the start of use of the device or the part to the present. According to this aspect, for each device or part of the heat source equipment where the device or part is used, a deterioration index that represents the current deterioration state can be quantified based on the elapsed time from the start of use.

[0010] In one aspect, the limit deterioration index determination unit is configured to determine the limit deterioration index based on at least one of the purpose of the heat source equipment, the actual operating time, the annual average load factor of the heat source equipment, and the usage environment. According to this aspect, it is possible to determine the limit deterioration index according to the usage status of the heat source equipment.

[0011] In one aspect, the service life upper limit value determiner is configured to set the deterioration index corresponding to the service life to a predetermined value, set a function indicating a relationship between the service life and the deterioration index, and determine the service life upper limit value based on the function and the limit deterioration index. According to this aspect, it is possible to determine an appropriate service life upper limit value according to the usage status of the heat source equipment.

[0012] In one aspect, the information generating unit is configured to generate maintenance proposal information related to a maintenance proposal for the heat source equipment based at least on the upper limit value of the service life. According to this aspect, multiple maintenance proposals such as update, overhaul, and replacement can be made for each device or part based on the upper limit value of the service life.

[0013] In one aspect, the usage status data includes information on the date and time when maintenance, repair, or replacement of the device or the part was performed. According to this aspect, it is possible to accurately display the upper limit of the service life and make maintenance suggestions based on the part replacement and maintenance records. [Effects of the Invention]

[0014] According to the present invention, it is possible to propose part replacement and maintenance in consideration of the degree of deterioration of the device or part according to the usage status and load status of the heat source equipment. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a schematic diagram illustrating the configuration of a heat source equipment maintenance support system 1 according to an embodiment. [Figure 2] 10 is a schematic diagram illustrating the operation of the risk level score determination unit 13. FIG. [Figure 3] 10 is a schematic diagram illustrating another operation of the risk level score determination unit 13. FIG. [Figure 4] 4 is a schematic diagram illustrating the operation of a limit deterioration index determining unit 14. FIG. [Figure 5] 10 is a graph illustrating another example of the operation of the limit deterioration index determining unit 14. [Figure 6] An example of the configuration of the useful life storage unit 16 will be described. [Figure 7] The operation of the upper limit value determining unit 17 will be described. [Figure 8] 10 is an example of a display screen. [Figure 9] 10 is an example of a display screen. [Figure 10] 10 is an example of a display screen. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, the present embodiment will be described with reference to the accompanying drawings. The accompanying drawings illustrate embodiments according to the principles of the present disclosure, but the drawings are for understanding the present disclosure and are not to be used to interpret the present disclosure in a limiting manner. The description in this specification is merely a typical example and does not limit the scope or application of the present disclosure in any way.

[0017] Although the present embodiment has been described in sufficient detail to enable those skilled in the art to implement the present disclosure, it should be understood that other implementations and forms are possible, and that changes in configuration and structure and substitutions of various elements are possible without departing from the scope and spirit of the technical ideas of the present disclosure. Therefore, the following description should not be interpreted as being limited thereto.

[0018] The configuration of a heat source equipment maintenance support system 1 according to an embodiment will be described with reference to Fig. 1. This system 1 is generally configured to include a data server 10, heat source equipment 20 to be controlled / managed, a control panel 30, a sensor group 40, a sensor repeater 50, and a management computer 60. The data server 10, the control panel 30, the sensor repeater 50, and the management computer 60 are connected to each other so as to be able to communicate with each other via a network NW, such as the Internet or a LAN (Local Area Network).

[0019] The heat source equipment maintenance support system 1 calculates a risk level score and other numerical values ​​that indicate the degree of risk of various problems (failure, shutdown, reduced output, abnormal output, etc.) occurring if the heat source equipment 20 continues to be used, according to the operating status of the heat source equipment 20, and furthermore, using factors such as the useful life of the devices and parts that make up the heat source equipment 20 as factors, objectively calculates a deterioration index and an upper limit on the number of years of use as numerical values ​​related to the safety of the devices and parts.

[0020] The data server 10 holds various data for managing and controlling the heat source equipment 20. The heat source equipment 20 to be controlled includes, for example, a turbo chiller, an absorption chiller / heater, a cooling tower, a pump, etc., but is not limited to any particular one. The heat source equipment maintenance support system 1 of this embodiment collects data from each piece of equipment according to the configuration of the heat source equipment 20 to be controlled / managed, and calculates and outputs various numerical values ​​for ensuring stable operation of the heat source equipment 20.

[0021] A control panel 30 is provided as a computer that executes integrated control of the heat source equipment 20. The control panel 30 outputs various voltages, communication signals, or control signals for controlling the heat source equipment 20, and receives feedback signals indicating the operation of the heat source equipment 20. It also includes a communication unit (not shown), and is connected to a network NW to transmit and receive various data to and from the data server 10.

[0022] The sensor group 40 measures various physical quantities (gas flow rate, current, voltage, power, temperature, humidity, pressure, vibration, amount of dust, etc.) in and around the heat source equipment 20 and outputs corresponding measurement signals. The acquired measurement signals are appropriately converted into digital values ​​and output to, for example, the sensor repeater 50, where they are used for control in the control panel 30 and are also collected in the data server 10.

[0023] The data server 10 and / or the management computer 60 are equipped with, by way of example, a design specification data storage unit 11, a maintenance data storage unit 12, a risk level score determination unit 13, a limit deterioration index determination unit 14, a useful life determination unit 15, a useful life memory unit 16, a usage life upper limit value determination unit 17, an information generation unit 18, and a display control unit 19, using a management program stored therein.

[0024] The design specification data storage unit 11 is a storage unit that stores design specification data of devices and parts that make up the heat source equipment 20. The maintenance data storage unit 12 is a storage unit that stores data related to maintenance that has already been performed on the heat source equipment 20 and maintenance that is scheduled to be performed on the heat source equipment 20.

[0025] The risk level score determination unit 13 is a part that determines the level of risk as a risk level score value when continuing to use the heat source equipment 20. Specifically, the risk level score value is calculated using factors such as the annual average load factor and annual operating hours of the heat source equipment 20, for example.

[0026] The limit deterioration index determination unit 14 is a part that determines the limit deterioration index of the heat source equipment 20 (the limit value that is acceptable as the deterioration index of the heat source equipment 20 that is the control target). The risk level score is a numerical value that indicates the possibility that various problems (failure, operation stoppage, output reduction, output abnormality, etc.) will occur if the heat source equipment 20 continues to be used, and the larger the numerical value, the greater the risk. In contrast, the limit deterioration index is the limit value (maximum value) of the deterioration index that indicates the degree of deterioration of the devices and parts that make up the heat source equipment 20. The limit deterioration index becomes a smaller value as the risk level increases.

[0027] The useful life determination unit 15 is a unit that determines the useful life of the devices and components that constitute the heat source equipment 20, and the useful life storage unit 16 is a unit that stores the useful life determined by the useful life determination unit 15 or a predetermined useful life. The useful life determination unit 15 may determine the useful life by directly using data described in the specifications of the devices and components, or may change the data described in the specifications according to data indicating the usage environment of the devices and components. Furthermore, instead of or in addition to using the data described in the specifications, the useful life storage unit 16 may acquire past usage data of the devices or components as big data and store the useful life determined according to the acquired data in the useful life storage unit 16.

[0028] The service life upper limit determination unit 17 determines the service life upper limit of the devices and parts included in the heat source equipment 20 (a value indicating the maximum number of years for which the devices and parts can continue to be used without maintenance or part replacement) based on the service life and the limit deterioration index. The information generation unit 18 compiles the various numerical values ​​(including the service life upper limit) determined as described above and various information about the heat source equipment 20 on one screen, and generates information about the safety of the devices or parts. The display control unit 19 executes control to display the information generated by the information generation unit 18 on the display of the management computer 60, for example.

[0029] The operation of the risk level score determination unit 13 will be described with reference to FIG. 2. As an example, the risk level score determination unit 13 determines the risk level score according to at least two factors that indicate the operating status of the heat source equipment 20 to be controlled / managed. In the example of FIG. 2, the risk level score is determined using the annual average load factor and annual operating hours of the heat source equipment 20 as factors. FIG. 2 is merely an example, and the risk level score can be determined by a combination of various factors that indicate the operating status of the heat source equipment 20. As factors, for example, data related to the usage status of the heat source equipment 20 (e.g., the purpose of the heat source equipment 20, the annual operating hours of the heat source equipment 20, the annual average load factor of the heat source equipment 20, the usage environment of the heat source equipment 20, the total overload operating time of the heat source equipment 20, the total number of times the heat source equipment 20 is turned on / off, etc.) can be considered, and at least one of these can be used. In other words, the risk level score may be determined by a combination of at least one or more factors. In addition to these factors, the risk level score can also be determined based on information regarding the date and time when maintenance, repair, or replacement of equipment or parts was performed.

[0030] The average annual load factor indicates, for example, the ratio between the average annual heat generation and the maximum heat load, and is calculated as follows: Load factor (%) = average annual heat generation (J) / maximum heat load (J) x 100, and is classified into, for example, four levels (less than 40%, 40-60%, 60-80%, 80% or more).

[0031] The annual operating hours indicate the actual operating hours per year for which the heat source equipment 20 is operated, and are classified into, for example, five levels (less than 1000 hours, 1000 to 2000 hours, 2000 to 3000 hours, 3000 to 4000 hours, 4000 hours or more, etc.). The risk level score determination unit 13 determines a risk level score in advance for each combination of such multiple factor classifications, and determines the risk level score according to factors (e.g., annual average load factor, annual operating hours) actually obtained for the heat source equipment 20 to be controlled. In the example of Figure 2, if the annual operating hours are long and the annual average load factor is high, the risk level score will also be high.

[0032] Here, risk level scores are predefined as 1 to 20. A risk level score of "20" indicates that the risk of operating the heat source equipment 20 is at the highest level, and that there is a very high possibility that equipment or component failures or operation shutdowns will occur within a short period of time. The lower the risk level score, the lower the possibility of such occurrences. Furthermore, as shown in FIG. 3, the risk level score may be uniquely determined based on the use of the heat source equipment 20. Furthermore, when there is no data on the annual average load factor or annual operating hours, such as at the start of use of the heat source equipment 20, the risk level score may be determined based on the use, and after the operating data is acquired, the risk level score may be determined according to the annual average load factor and annual operating hours, as described above.

[0033] The operation of the limit deterioration index determination unit 14 will be described with reference to the table in Fig. 4. The limit deterioration index determination unit 14 is a part that determines the limit deterioration index as a limit value that is acceptable as a deterioration index of the heat source equipment 20 to be controlled, and as described above, the higher the risk level score, the smaller the limit deterioration index. In the example of Fig. 4, the risk level score and the limit deterioration index are stored in one-to-one correspondence, and the limit deterioration index can be determined according to the risk level score obtained by the risk level score determination unit 13. For example, when the risk level is divided into 1 to 20 stages, the upper limit of the limit deterioration index of a part is set to 61 to 80%, with 80% or more being considered dangerous.

[0034] The higher the risk level score (i.e., the higher the load and the longer the heat source equipment 20 is used), the faster the deterioration of the equipment and parts of the heat source equipment 20, and therefore earlier maintenance, repair, and replacement are required. For this reason, the limit deterioration index determination unit 14 stores a numerical value table in advance so that the higher the risk level score, the lower the limit deterioration index, and determines the limit deterioration index according to the risk level score determined by the risk level score determination unit 13 or the risk level score selected from the application. As described with reference to Figures 2 to 4, the limit deterioration index of the equipment or parts can be determined according to the usage status of the heat source equipment 20.

[0035] Instead of having a table that defines the relationship between risk level scores and marginal deterioration indices as in Figure 4, a function that shows the relationship between risk level scores and marginal deterioration indices may be stored, and the marginal deterioration indices may be calculated and output according to the function with the risk level scores as input, as in Figure 5. When the risk level scores are calculated as non-integer values, the function format as in Figure 5 is preferable.

[0036] An example of the configuration of the useful life determination unit 15 will be described with reference to Fig. 6. For example, as shown in Fig. 6, data on the useful life of component A in the heat source equipment 20 can be acquired as a histogram from, for example, an external server (not shown). Data such as that shown in Fig. 6 can be acquired separately from an external inspection agency or the like, or may be acquired as big data.

[0037] In the histogram of FIG. 6, the horizontal axis represents the time from the start of use to failure, and the vertical axis represents the number of samples (number of samples). The median of this histogram can be determined as the useful life of part A. In the graph of FIG. 6, the useful life of part A is determined to be 10.4 years. The deterioration index of part A, which has been used for that useful life (10.4 years), is defined as, for example, 100%. The useful life storage unit 16 stores the useful life calculated based on the data shown in FIG. 6. Instead of the useful life calculated based on big data such as that shown in FIG. 6, a useful life calculated using a different method may be stored in the useful life storage unit 16. The useful life can be calculated and stored for each device or component of the heat source equipment 20. For example, when a component commonly used in multiple devices is calculated for each device and for each component, the calculated useful life may differ depending on the sales period of the device and the characteristics of the device. Therefore, if the useful life is calculated for each device or component, a more accurate useful life can be selected.

[0038] The operation of the service life upper limit value determination unit 17 will be described with reference to Fig. 7. The service life upper limit value determination unit 17 is a unit that determines and outputs an upper limit value for the service life of devices or parts that make up the heat source equipment 20. Specifically, the service life upper limit value determination unit 17 sets the deterioration index for the service life (e.g., the above-mentioned 10.4 years) of one device or part stored in the service life storage unit 16 to a predetermined value (100%), and plots a linear function (graph) assuming that the deterioration index of the unused device or part is 0%.

[0039] The service life upper limit value determination unit 17 inputs the limit deterioration index (e.g., 69%) determined by the limit deterioration index determination unit 14 into this linear function (graph) and calculates the corresponding service life upper limit value (e.g., 7.2 years). As described above, the more severe the operating conditions of the equipment or parts, the smaller the limit deterioration index, and the smaller the service life upper limit value determined by the service life upper limit value determination unit 17. In addition, the current deterioration index of the parts (e.g., 62.5%) is calculated from the number of years since the equipment or parts were used (e.g., 6.5 years). Furthermore, as an index for making maintenance suggestions, the graph area is classified into, for example, three levels (0-40% as the first region, 40-80% as the second region, and 80-100% as the third region)). When the operating time of the heat source equipment moves to the second region, a maintenance menu can be proposed. In addition, when the operation time moves from the first region to the second region or from the second region to the third region, the color scheme of the maintenance menu display screen can be changed.

[0040] The information generator 18 collects the risk level scores, marginal deterioration index, upper limit value of service life, etc., determined in this manner, and generates display data that can be displayed as a display screen for the recommended replacement parts screen. The display controller 19 executes display control for displaying the generated display data, for example, on the display screen of the management computer 60. FIG. 8 shows an example of the display screen, displaying data identifying the heat source equipment 20, such as a display field A1 for the site name, machine name (machine name), and serial number (production number) of the heat source equipment 20 to be controlled, a display field A2 for the installation date, trial run date, estimate creation date, and number of years since the trial run date, as well as a display field A3 for the risk level scores, marginal deterioration index, a display field A4 for the current deterioration index of the equipment and parts, and the upper limit value of service life. The recommended replacement parts screen also includes a button group A5 that displays buttons for outputting (printing) a maintenance proposal and estimate, a button for displaying a screen for instructing work order and schedule adjustment, and a button for moving to a maintenance proposal screen.

[0041] By looking at this display screen, the operator (or user) of the management computer 60 can determine which parts of the heat source equipment 20 require maintenance, repair, or replacement. Furthermore, the names of parts recommended for replacement can be displayed in different colors according to the deterioration index value (for example, 40% or more), thereby alerting the operator (or user).

[0042] FIG. 9 shows a screen for displaying various numerical values ​​and for making maintenance suggestions based on the obtained numerical values. The screen of FIG. 9 can also be generated by the information generating unit 18. This maintenance suggestion screen can include, for example, a display field A6 for the presence or absence of a pre-alarm and its details, the presence or absence of an error and its details, and the results of an analysis of its cause, as well as a display field A7 for multiple maintenance suggestions, such as suggestions related to the pre-alarm or error, a suggestion for a refrigerator overhaul, a suggestion for a part replacement, and an inspection by a maintenance technician. Furthermore, various buttons A8 are displayed near the suggestion content (suggestions 1 to 4) for displaying an estimate of the costs required if the maintenance suggestion is carried out or for moving to a screen that explains the details of optimal operation.

[0043] FIG. 10 shows an example of the quotation screen displayed when the "Quotation Screen 2" button for Proposal 2 is pressed. In FIG. 10, a display field A9 is displayed, listing the name, unit price, delivery date, and quantity of the part recommended for replacement. Further details may be included. Next to the display field A9, which displays the name of the recommended part, a check box A10 is displayed to indicate whether or not to add the part to the quotation. Selecting the part includes the quotation. The check box can be omitted. A display field A11 is also provided, listing the labor cost, parts cost, transportation cost, consumable cost, tool rental, and miscellaneous expenses for the maintenance. The quotation screen also includes a button group A12, which displays a maintenance proposal, a button for printing the quotation, a button for displaying a screen for instructing work order and schedule adjustment, and a button for returning to the maintenance proposal screen (FIG. 9). If the user wants to view more details about Proposal 2 after viewing this quotation screen, they can press the button group A12 in the lower right corner to print the maintenance proposal, print the quotation, place a work order, schedule adjustment, and so on.

[0044] As described above, the heat source equipment maintenance support system 1 according to the embodiment can present the degree of deterioration of the devices and parts to be controlled, as well as the urgency of maintenance, repair, and replacement, as numerical values. The presented numerical values ​​are calculated based on the usage status of the heat source equipment and data on the useful lives collected about the devices and parts, and are objective and evidence-based, making it easier for the operator (or user) to grasp the appropriate timing for maintenance, repair, and replacement, and to be convinced of the necessity of maintenance, repair, and replacement, as well as the costs involved.

[0045] The present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those including all of the described configurations. Furthermore, it is possible to replace part of the configuration of one embodiment with the configuration of another embodiment, or to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is possible to add, delete, or replace part of the configuration of each embodiment with other configurations. [Explanation of symbols]

[0046] 1. Heat source equipment maintenance support system 10...Data server 11...Design specification data storage section 12...Maintenance data storage section 13...Risk level score determination section 14...Determining limit deterioration index 15...Service life determination section 16...Service life storage section 17...Usage age upper limit determination section 18...Information generation section 19...Display control unit 20…Heat source equipment 30...Control panel 40...Sensor group 50...Sensor repeater 60...Administrative computer NW...Network

Claims

1. a limit deterioration index determination unit that determines a limit deterioration index, which is a limit value of a deterioration index that indicates the degree of deterioration of a device or part that constitutes the heat source equipment, according to usage status data that indicates the usage status of the heat source equipment; a useful life storage unit that stores the useful life of the device or the part; a service life upper limit value determination unit that determines an upper limit value of the service life of the device or the part of the heat source equipment based on the service life and the limit deterioration index; an information generating unit that generates information about the safety level of the device or the part, including an upper limit value of the service life of the device or the part; A heat source equipment maintenance support system comprising:

2. The useful life storage unit The heat source equipment maintenance support system of claim 1, wherein the useful life is determined by a useful life determination unit that determines the useful life for each device or each component according to past usage data, and the determined useful life is stored, or a useful life that has been determined in advance for each device or each component is stored.

3. the information generating unit generates a current deterioration index of the device or the part based on the elapsed time from the start of use of the device or the part to the present. The heat source equipment maintenance support system according to claim 1.

4. The heat source equipment maintenance support system according to claim 1, wherein the limit deterioration index determination unit determines the limit deterioration index based on at least one of the purpose of the heat source equipment, the actual operating time, the annual average load factor of the heat source equipment, or the usage environment.

5. The usage age upper limit value determination unit setting the deterioration index corresponding to the useful life to a predetermined value, and setting a function indicating a relationship between the useful life and the deterioration index; The heat source equipment maintenance support system according to claim 1 , wherein the upper limit value of service life is determined based on the function and the limit deterioration index.

6. The heat source equipment maintenance support system according to claim 1 , wherein the information generating unit generates maintenance proposal information related to a proposal for maintenance of the heat source equipment based at least on the upper limit value of the years of use.

7. The heat source equipment maintenance support system according to claim 1 , wherein the usage data includes information regarding dates and times when maintenance, repair, or replacement of the device or the component was performed.

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