Monitoring device, threshold setting device, factor analysis device, and monitoring method

Abstract

To provide a technique capable of easily estimating a factor when an abnormality occurs while suppressing the trouble of setting a standard for abnormality determination, regarding a monitored device which heat energy goes into and out from, including heat generation and absorption.SOLUTION: A heat energy monitoring device 20 according to an embodiment of the present disclosure includes: a heat balance calculation unit 201 that acquires data about a state of a sterilizer 50, and based on the data, calculates multiple types of heat energy (heat amounts Q1 to Q5) that constitute heat balance of the sterilizer 50; and a monitoring unit 203 that monitors presence or absence of deviation of the heat energy (heat amount QX) of a target type from a normal range defined by upper and lower threshold values for each of the multiple types of heat energy (heat amounts Q1 to Q5) calculated by the heat balance calculation unit 201.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to monitoring devices and the like. [Background technology]

[0002] For example, a technique is known for determining whether or not a monitored device has an abnormality by monitoring status data (measured values) that indicate the status of the monitored device (see Patent Document 1).

[0003] Patent Document 1 discloses a technique for monitoring the flame voltage of an industrial furnace as a monitored device, and transmitting alarm information to the outside when the flame voltage falls below a threshold value.

[0004] Further, for example, a technique is known in which many types of status data representing the status of a monitored device are compressed into a relatively small number of variables, and the monitored device is monitored using the compressed variables (see Patent Document 2).

[0005] Patent Document 2 discloses a technique for reducing a plurality of status data for a refrigeration cycle device as a monitored device to one Mahalanobis distance and monitoring for abnormalities using the Mahalanobis distance. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2019-100572 A [Patent Document 2] JP 2005-345096 A Summary of the Invention [Problem to be solved by the invention]

[0007] However, for example, when monitoring status data of a monitored device as in Patent Document 1, if the types of status data to be monitored are relatively large, it becomes necessary to prepare criteria for determining abnormalities for each type, which can result in a lot of work.

[0008] On the other hand, for example, as in Patent Document 2, reducing multiple types of status data to fewer variables reduces the effort required to prepare criteria for abnormality determination, but it may not be easy to determine which type of status data corresponds to which status item when an abnormality occurs.

[0009] In view of the above problems, the objective of the present invention is to provide a technology that can easily estimate the cause of an abnormality when it occurs, while reducing the effort required to set standards for determining an abnormality, for monitored devices where thermal energy, including heat generation and heat absorption, flows in and out. [Means for solving the problem]

[0010] In order to achieve the above object, in one embodiment of the present disclosure, Obtaining data regarding the status of the monitored equipment; Acquired a thermal energy calculation unit that calculates a plurality of types of thermal energy constituting an entire heat balance in the monitored device based on the data; a monitoring unit that monitors whether or not the heat energy of a target type deviates from a predetermined range defined by an upper threshold and a lower threshold for each of the plurality of types of heat energy calculated by the heat energy calculation unit. 、 The data on the state of the monitored device includes data on dynamic states of the monitored device, including temperatures, pressures, and flow rates, and data on static states of the monitored device, including operating states; The monitoring unit varies at least one of the upper limit threshold and the lower limit threshold for each type of static state of the monitoring target device. R, A monitoring device is provided.

[0011] In another embodiment of the present disclosure, A threshold setting device for setting the upper limit threshold and the lower limit threshold used in the above-mentioned monitoring device, a setting unit that sets the upper limit threshold and the lower limit threshold based on time series data of the plurality of types of thermal energy calculated by the thermal energy calculation unit, A threshold setting device is provided.

[0012] In still another embodiment of the present disclosure, When the monitoring device detects a deviation of a predetermined thermal energy from the plurality of types of thermal energy from the predetermined range, heat an extraction unit that extracts a status item that indicates a cause of deviation of the predetermined thermal energy from the predetermined range from a plurality of status items that indicate a state of the monitored device related to energy; A factor analysis device is provided.

[0013] In still another embodiment of the present disclosure, A monitoring method executed by a monitoring device, comprising: Obtaining data regarding the status of the monitored equipment; Acquired a heat energy calculation step of calculating a plurality of types of heat energy constituting an entire heat balance in the monitored device based on the data; A monitoring step of monitoring whether or not the heat energy of the target type deviates from a predetermined range defined by an upper threshold and a lower threshold for each of the plurality of types of heat energy calculated in the heat energy calculation step. fruit , The data on the state of the monitored device includes data on dynamic states of the monitored device, including temperatures, pressures, and flow rates, and data on static states of the monitored device, including operating states; In the monitoring step, at least one of the upper limit threshold and the lower limit threshold is made different for each type of static state of the monitoring target device. A monitoring method is provided. Effect of the Invention

[0014] According to the above-described embodiment, for a monitored device in which thermal energy, including the generation and absorption of heat, flows in and out, it is possible to easily estimate the cause of an abnormality while reducing the effort required for setting criteria for determining an abnormality. [Brief description of the drawings]

[0015] [Figure 1]FIG. 1 is a diagram illustrating an example of a configuration of a thermal energy monitoring system. [Diagram 2] FIG. 1 is a diagram showing an example of the configuration of a sterilization device as a monitoring target of a thermal energy monitoring system. [Diagram 3] FIG. 2 is a diagram illustrating an example of a hardware configuration of a thermal energy monitoring device. [Figure 4] 4 is a flowchart illustrating an example of a process related to monitoring of thermal energy by a thermal energy monitoring device. [Diagram 5] 10 is a flowchart illustrating an example of a process related to setting of a threshold value by the monitoring support device. [Figure 6] FIG. 13 is a diagram showing an example of a threshold setting input screen. [Figure 7] FIG. 13 is a diagram showing an example of a threshold final setting screen. [Figure 8] FIG. 13 is a diagram illustrating an example of an abnormality occurrence history screen. [Figure 9] 13 is a diagram illustrating an outline of a processing flow regarding an abnormality cause analysis by the monitoring support device. [Figure 10] FIG. 13 is a diagram showing an example of an analysis result screen. [Figure 11] 13 is a screen showing another example of the analysis result screen. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, an embodiment will be described with reference to the drawings.

[0017] [Overview of the thermal energy monitoring system] First, a thermal energy monitoring system 1 according to the present embodiment will be described with reference to FIG.

[0018] FIG. 1 is a diagram showing an example of the configuration of a thermal energy monitoring system 1 according to this embodiment.

[0019] The thermal energy monitoring system 1 according to this embodiment monitors the balance of thermal energy in the sterilization device 50 as a monitoring target, thereby determining the presence or absence of an abnormality.

[0020] 1, the thermal energy monitoring system 1 includes a measuring device 10, a thermal energy monitoring device 20, and a monitoring support device 30. The thermal energy monitoring system 1 also cooperates with a production management system 40.

[0021] The measuring device 10 is attached to the sterilization device 50 or installed around the sterilization device 50, measures various states of the sterilization device 50, and outputs measurement data related to the dynamic state of the sterilization device 50. The dynamic state of the sterilization device 50 means a state that can change dynamically with the operation of the sterilization device 50. The dynamic state of the sterilization device 50 includes, for example, the temperature state, pressure state, and flow rate state inside the sterilization device 50. The measurement data output from the measuring device 10 is taken into the thermal energy monitoring device 20 through a predetermined communication line. The predetermined communication line is, for example, a one-to-one communication line. The predetermined communication line may also be, for example, a local network (LAN: Local Area Network) in a factory where the sterilization device 50 is installed, such as a field network. The predetermined communication line may also include, for example, a wide area network (WAN: Wide Area Network) outside the factory where the sterilization device 50 is installed. The wide area network may include, for example, a mobile communication network with a base station as a terminal, a satellite communication network using a communication satellite, the Internet network, and the like. Furthermore, the predetermined communication line may include a short-range communication line based on a wireless communication standard such as WiFi or Bluetooth (registered trademark).

[0022] The thermal energy monitoring device 20 (an example of a monitoring device) monitors the operating state of the sterilization device 50. Specifically, the thermal energy monitoring device 20 monitors the balance of thermal energy of the sterilization device 50 based on the measurement data acquired from the measuring device 10 and the data on the static state of the sterilization device 50 acquired from the production management system 40, and determines whether or not there is an abnormality in the sterilization device 50. The thermal energy monitoring device 20 may be installed, for example, in the same factory as the sterilization device 50. Also, the thermal energy monitoring device 20 may be installed, for example, in a facility (for example, a monitoring center, etc.) outside the factory in which the sterilization device 50 is installed. The thermal energy monitoring device 20 is, for example, a server device. In this case, the thermal energy monitoring device 20 may be a cloud server or an on-premise server, or may be an edge server. Also, the thermal energy monitoring device 20 may be, for example, a terminal device such as a computer terminal in the factory in which the sterilization device 50 is installed.

[0023] The monitoring support device 30 (an example of a threshold setting device and a factor analysis device) supports the user in setting a criterion (a threshold described later) for monitoring the sterilization device 50 by the thermal energy monitoring device 20 and in analyzing factors when the thermal energy monitoring device 20 determines that the sterilization device 50 is abnormal. Specifically, the monitoring support device 30 acquires various data from the thermal energy monitoring device 20 through a predetermined communication line, and sets a criterion (threshold) for monitoring and analyzes factors for abnormalities in the sterilization device 50 based on the acquired data. The monitoring support device 30 may be installed, for example, in the same factory as the sterilization device 50 together with the thermal energy monitoring device 20. In this case, the thermal energy monitoring device 20 may be installed, for example, in a location relatively close to the sterilization device 50 in the factory, and the monitoring support device 30 may be installed, for example, in a location where a user of the monitoring support device 30, such as a worker or a manager in a management office in the factory, performs management work related to the factory. The monitoring support device 30 may also be installed in a facility (for example, a monitoring center, etc.) outside the factory in which the sterilization device 50 is installed. The monitoring support device 30 is, for example, a server device. In this case, the monitoring support device 30 may be a cloud server, an on-premise server, or an edge server. The monitoring support device 30 may also be, for example, a terminal device such as a computer terminal installed in a management office in a factory.

[0024] The production management system 40 manages products produced in a factory. Specifically, the production management system 40 manages the quality of products produced in a factory. For example, the production management system 40 controls the operating state of a production line. Specifically, the production management system 40 controls various devices including a sterilization device 50 installed in the production line. The production management system 40 transmits information on the static state of the sterilization device 50 (hereinafter, "status information") to the thermal energy monitoring device 20 through a predetermined communication line. The static state of the sterilization device 50 means, for example, a state that does not basically change unless there is an operation or control command from outside when the sterilization device 50 is operating. The static state of the sterilization device 50 includes the operation mode of the sterilization device 50 and the type of product sterilized by the sterilization device 50 (hereinafter, "product type"). The product type is information that indirectly indicates the control conditions of the sterilization device 50 (for example, various temperature conditions, pressure conditions, etc.). This is because the control conditions of the sterilization device 50 differ depending on the product type, and the product type and the control conditions are associated with each other. The operation mode of the sterilization apparatus 50 is preset to a plurality of types, such as "operating", "standby", and "stopped". The sterilization apparatus 50 is basically operated in one operation mode, and the operation mode may be switched, for example, when the type of product to be sterilized is switched. For example, the operation mode of the sterilization apparatus 50 can be appropriately set (changed) in response to an operation by an operator or the like from an input unit of the sterilization apparatus 50 or an operation terminal device of the production management system 40.

[0025] [Outline of the sterilization equipment] Next, the outline of the sterilization device 50 will be described.

[0026] FIG. 2 is a diagram showing an example of the configuration of a sterilization device 50 as a monitoring target of the thermal energy monitoring system 1. As shown in FIG.

[0027] The sterilization device 50 sterilizes products produced in a factory. The sterilization device 50 may sterilize beverages produced in a factory, for example. The product passing through the sterilization device 50 may be a beverage already filled in a packaging container (hereinafter, for convenience, a "solid beverage"), or may be a beverage that flows as a liquid before being filled in a packaging container (hereinafter, for convenience, a "non-solid beverage").

[0028] As shown in FIG. 2, the sterilization device 50 includes a product passage 51, a high-temperature water circulation passage 52, a pump 52A, a steam inflow passage 53, a drainage passage 54, a cooling water passage 55, a heating section 56, and a cooling section 57.

[0029] The product passage 51 is a passage through which the product (beverage) flows, passes through the inside of the sterilization device 50, and then flows out to the outside.

[0030] The high-temperature water circulation path 52 is a path for circulating water (high-temperature water) at a relatively high temperature. A pump 52A is installed in the high-temperature water circulation path 52, and the high-temperature water is circulated by the pump 52A.

[0031] The steam inflow path 53 is a path that allows extremely high temperature steam to flow into the high-temperature water circulation path 52. This makes it possible to maintain the temperature of the high-temperature water circulating through the high-temperature water circulation path 52 at a relatively high temperature.

[0032] The drainage path 54 discharges excess high-temperature water from the high-temperature water circulation path 52 to the outside. This is because the amount of high-temperature water in the high-temperature water circulation path 52 increases due to the inflow of steam.

[0033] The cooling water passage 55 is a passage through which cooling water for cooling the products flows in from the outside, passes through the inside of the sterilization device 50, and then flows out to the outside.

[0034] The heating unit 56 exchanges heat between the high-temperature water in the high-temperature water circulation path 52 and the product (beverage) in the product passage path 51, and heats and sterilizes the beverage in the product passage path 51. The heating unit 56 is disposed in the front half of the product passage path 51.

[0035] The cooling section 57 exchanges heat between the cooling water in the cooling water passage 55 and the product (beverage) in the product passage 51, and cools the product whose temperature has increased during heat sterilization by the heating section 56. The cooling section 57 is disposed in the rear half of the product passage 51.

[0036] The sterilizer 50 is controlled by the production management system 40 as described above. Specifically, the sterilizer 50 is controlled so that the temperature of the product in the heating section 56 is equal to or higher than a predetermined value. This allows the sterilizer 50 to appropriately perform heat sterilization of the product under the control of the production management system 40. In addition, the sterilizer 50 is controlled so that the temperature of the product after passing through the cooling section 57 drops to a predetermined value or lower.

[0037] [Details of the thermal energy monitoring system] Next, the thermal energy monitoring system 1 will be described in detail with reference to FIGS. 3 to 11 in addition to FIG.

[0038] <Configuration of measurement equipment> 1, the measurement device 10 includes a temperature sensor 11, a pressure sensor 12, and a flow rate sensor 13. The measurement device 10 may also include other types of sensors capable of measuring physical states of the sterilization device 50 other than the temperature state, the pressure state, and the flow rate state.

[0039] The temperature sensor 11 measures the temperature inside the sterilization device 50. The temperature sensor 11 includes, for example, a temperature sensor that measures the temperature T1 of the steam flowing in from the steam inflow path 53 (hereinafter, "steam temperature"). The temperature sensor 11 also includes, for example, a temperature sensor that measures the temperature T2 of the wastewater discharged from the wastewater path 54 (hereinafter, "wastewater temperature"). The temperature sensor 11 also includes, for example, a temperature sensor that measures the temperature T3 of the product (beverage) at the inlet of the product passage path 51 (hereinafter, "product inlet temperature"). The temperature sensor 11 also includes, for example, a temperature sensor that measures the temperature T4 of the product (beverage) at the outlet of the product passage path 51 (hereinafter, "product outlet temperature"). The temperature sensor 11 also includes, for example, a temperature sensor that measures the temperature T5 of the cooling water at the inlet of the cooling water passage path 55 (hereinafter, "cooling water inlet temperature"). The temperature sensor 11 also includes a temperature sensor that measures the temperature T6 of the cooling water at the outlet of the cooling water passage 55 (hereinafter, "cooling water outlet temperature"), for example.

[0040] The pressure sensor 12 measures the pressure inside the sterilization device 50. The pressure sensor 12 includes, for example, a pressure sensor that measures the pressure P1 of the steam flowing in from the steam inflow path 53 (hereinafter, "steam pressure"). The pressure sensor 12 also includes, for example, a pressure sensor that measures the pressure P2 of the wastewater discharged from the wastewater path 54 (hereinafter, "drain pressure").

[0041] The flow sensor 13 measures the flow rate inside the sterilization device 50. The flow sensor 13 includes, for example, a flow sensor that measures the flow rate of steam flowing in from the steam inflow path 53 (hereinafter, "steam flow rate") F1. The flow sensor 13 also includes, for example, a flow sensor that measures the flow rate of wastewater discharged from the drainage path 54 (hereinafter, "drainage flow rate") F2. The flow sensor 13 also includes, for example, a flow sensor that measures the flow rate of the product (beverage) at the inlet of the product passage path 51 (hereinafter, "product inlet flow rate") F3. The flow sensor 13 also includes, for example, a flow sensor that measures the flow rate of the product (beverage) at the outlet of the product passage path 51 (hereinafter, "product outlet flow rate") F4. The flow sensor 13 also includes, for example, a flow sensor that measures the flow rate of cooling water at the inlet of the cooling water passage path 55 (hereinafter, "cooling water inlet flow rate") F5. The flow rate sensor 13 also includes a flow rate sensor that measures the flow rate of the cooling water at the outlet of the cooling water passage 55 (hereinafter, "cooling water outlet flow rate") F6, for example.

[0042] <Configuration of the thermal energy monitoring device> FIG. 3 is a diagram showing an example of a hardware configuration of the thermal energy monitoring device 20. As shown in FIG.

[0043] The functions of the thermal energy monitoring device 20 may be realized by any hardware, or any combination of hardware and software, etc. As shown in Fig. 3, for example, the thermal energy monitoring device 20 includes a drive device 21, an auxiliary storage device 22, a memory device 23, a CPU 24, an interface device 25, a display device 26, and an input device 27, each of which is connected by a bus B.

[0044] A program for realizing various functions of the thermal energy monitoring device 20 is provided by, for example, a portable recording medium 21A. The recording medium 21A includes, for example, a CD-ROM (Compact Disc Read Only Memory), a DVD-ROM (Digital Versatile Disc Read Only Memory), or a USB (Universal Serial Bus) memory. When the recording medium 21A on which the program is recorded is set in the drive device 21, the program is installed in the auxiliary storage device 22 from the recording medium 21A via the drive device 21. The program may also be downloaded from another computer via a predetermined communication line and installed in the auxiliary storage device 22.

[0045] The auxiliary storage device 22 stores various installed programs, as well as necessary files, data, and the like.

[0046] When an instruction to start a program is received, the memory device 23 reads the program from the auxiliary storage device 22 and stores it.

[0047] The CPU 24 executes various programs stored in the memory device 23, and realizes various functions related to the thermal energy monitoring device 20 in accordance with the programs.

[0048] The interface device 25 is used as an interface for connecting to a predetermined communication line.

[0049] The display device 26 displays a GUI (Graphical User Interface) in accordance with a program executed by the CPU 24, for example.

[0050] The input device 27 is used to allow an operator or manager of the thermal energy monitoring device 20 to input various operation instructions related to the thermal energy monitoring device 20 .

[0051] 1, the thermal energy monitoring device 20 includes a heat balance calculation unit 201, a storage unit 202, and a monitoring unit 203. The functions of the heat balance calculation unit 201 and the monitoring unit 203 may be realized, for example, by a program installed in the auxiliary storage device 22 being loaded into the memory device 23 and executed by the CPU 24. The function of the storage unit 202 may be realized, for example, by a storage area defined in the auxiliary storage device 22.

[0052] The heat balance calculation unit 201 (an example of a thermal energy calculation unit) performs calculations related to the heat balance of the sterilization apparatus 50. Specifically, the heat balance calculation unit 201 calculates multiple types of thermal energy that constitute the heat balance of the sterilization apparatus 50 based on the measurement data successively acquired from the measuring device 10 for each predetermined control period.

[0053] The multiple types of heat energy constituting the heat balance of the sterilization device 50 include steam heat Q1, wastewater exhaust heat Q2, product take-out heat Q3, cooling water exhaust heat Q4, and other exhaust heat Q5. Steam heat Q1 represents the heat (heat energy) of steam flowing in from the steam inflow path 53. Wastewater exhaust heat Q2 represents the heat (heat energy) of wastewater discharged from the drainage path 54. Product take-out heat Q3 represents the heat (heat energy) taken out of the sterilization device 50 by the product passing through the product passage path 51. Cooling water exhaust heat Q4 represents the heat (heat energy) discharged to the outside through the cooling water passing through the cooling water passage path 55. Other exhaust heat Q5 represents the heat (heat energy) discharged from the sterilization device 50 other than the wastewater exhaust heat Q2, product take-out heat Q3, and cooling water exhaust heat Q4. Hereinafter, the steam calorific value Q1, the wastewater calorific value Q2, the product export calorific value Q3, the cooling water exhaust calorific value Q4, and the other exhaust calorific value Q5 may be collectively referred to as the calorific values ​​Q1 to Q5. Also, any one of the steam calorific value Q1, the wastewater calorific value Q2, the product export calorific value Q3, the cooling water exhaust calorific value Q4, and the other exhaust calorific value Q5 may be individually referred to as the calorific value QX (X: an integer from 1 to 5).

[0054] The relationship (heat balance) of the following equation (1) is established between the steam heat quantity Q1, the wastewater heat quantity Q2, the product export heat quantity Q3, the cooling water heat quantity Q4, and other waste heat quantity Q5.

[0055]

number

[0056] The heat balance calculation unit 201 calculates the steam heat quantity Q1 using, for example, the following expressions (2) and (3).

[0057]

number

[0058] Furthermore, the heat balance calculation unit 201 may calculate the steam heat quantity Q1, for example, by using the following formula (4).

[0059]

number

[0060] Incidentally, the "saturated steam enthalpy", "specific volume" and "density" vary depending on the steam temperature T1 and the steam pressure P1, respectively, and are calculated using a saturated steam table based on the measured values ​​of the steam temperature T1 and the steam pressure P1. Data corresponding to the saturated steam table is stored in advance in, for example, the auxiliary storage device 22.

[0061] Further, the heat balance calculation unit 201 calculates the amount of wastewater exhaust heat Q2, for example, by using the following formula (5).

[0062]

number

[0063] Incidentally, the "specific heat of water" is registered in the auxiliary storage device 22 or the like as a predefined value (e.g., 4.22). The "steam mass flow rate" is calculated from the above-mentioned formula (3). The "wastewater inlet temperature" corresponds to the temperature of the high-temperature water before the steam flows in, and may be predefined, for example, simply as being equal to the air temperature in the factory (e.g., 20°C), or a specific measured value may be used. In the latter case, the temperature sensor 11 includes a temperature sensor that measures the wastewater inlet temperature.

[0064] Further, the heat balance calculation unit 201 calculates the product take-out heat amount Q3 using, for example, the following formula (6).

[0065]

number

[0066] In addition, in formula (6), the product inlet flow rate F3 may be replaced by the product outlet flow rate F4, or the average value of the product inlet flow rate F3 and the product outlet flow rate F4, etc. The same may be true for formulas (7) and (8) below.

[0067] Further, the heat balance calculation unit 201 may more precisely calculate the product take-out heat amount Q3 using, for example, the following formula (7) or formula (8).

[0068]

number

[0069] Incidentally, formula (7) corresponds to the case where the product to be sterilized by the sterilization device 50 is a non-solid beverage, and formula (8) corresponds to the case where the product to be sterilized by the sterilization device 50 is a solid beverage.

[0070] Further, the heat balance calculation unit 201 calculates the coolant waste heat amount Q4 using, for example, the following formula (9).

[0071]

number

[0072] In addition, in formula (9), the cooling water inlet flow rate F5 may be replaced with the cooling water outlet flow rate F6, or an average value of the cooling water inlet flow rate F5 and the cooling water outlet flow rate F6, or the like.

[0073] Further, the heat balance calculation unit 201 calculates the other waste heat amount Q5, for example, by using the following formula (10) which is derived from the above formula (1).

[0074]

number

[0075] The storage unit 202 stores thresholds 202A used by the monitoring unit 203. The thresholds 202A include an upper threshold QX_THU and a lower threshold QX_THL (X: an integer from 1 to 5) defined for each of the amounts of heat Q1 to Q5. Furthermore, the thresholds 202A (upper threshold QX_THU and lower threshold QX_THL) may be defined for each type of static state (for example, operation mode or product type) of the sterilization device 50 and stored in the storage unit 202, for example.

[0076] The monitoring unit 203 monitors whether the amounts of heat Q1 to Q5 calculated sequentially by the heat balance calculation unit 201 deviate from a normal range (an example of a predetermined range) defined by the threshold value 202A. The monitoring unit 203 grasps the static state of the current operation mode and product type of the sterilization device 50, for example, based on status information sequentially acquired from the production management system 40. Then, the monitoring unit 203 monitors whether the target amount of heat QX deviates from the normal range for each amount of heat Q1 to Q5, using the threshold value 202A that matches the current static state of the sterilization device 50. If all the amounts of heat Q1 to Q5 do not deviate from the normal range, the monitoring unit 203 outputs a monitoring result indicating normality, and if some or all of the amounts of heat Q1 to Q5 deviate from the normal range, the monitoring unit 203 outputs a monitoring result indicating abnormality. Naturally, the type of amount of heat that deviates from the normal range among the amounts of heat Q1 to Q5 is specified in the monitoring result indicating abnormality.

[0077] The monitoring unit 203 transmits the monitoring results, the latest measurement data from the measuring device 10, the latest status information from the production management system 40, and the latest calculation results of the heat balance (heat quantities Q1 to Q5) by the heat balance calculation unit 201 to the monitoring support device 30 at each predetermined control period.

[0078] <Processing flow of the thermal energy monitoring device> 4 is a flowchart outlining an example of a process related to monitoring of thermal energy (heat amounts Q1 to Q5) by the thermal energy monitoring device 20. This flowchart is repeatedly executed, for example, at predetermined control intervals.

[0079] 4, in step S102, the heat balance calculation unit 201 performs a heat balance calculation. Specifically, the heat balance calculation unit 201 calculates the amounts of heat Q1 to Q5 based on the measurement data of the measurement device 10.

[0080] When the process of step S102 is completed, the thermal energy monitoring device 20 proceeds to step S104.

[0081] In step S104, the monitoring unit 203 acquires the thresholds 202A (upper limit threshold QX_THU and lower limit threshold QX_THL) that are suitable for the latest status information for each of the amounts of heat Q1 to Q5, based on the latest status information.

[0082] When the process of step S104 is completed, the thermal energy monitoring device 20 proceeds to step S106.

[0083] In step S106, monitoring unit 203 determines whether it is within the monitoring period. The monitoring period is, for example, a period excluding the status information of sterilization apparatus 50, i.e., a predetermined time (for example, several minutes to several tens of minutes) after the static state is switched. This is because immediately after the static state of sterilization apparatus 50 is switched, it may take some time for the dynamic state of sterilization apparatus 50 to stabilize. If it is within the monitoring period, monitoring unit 203 proceeds to step S108, and if it is not within the monitoring period, proceeds to step S112.

[0084] In step S108, the monitoring unit 203 monitors for each of the heat quantities Q1 to Q5 calculated by the heat balance calculation unit 201 whether or not it deviates from the normal range defined by the upper threshold QX_THU and the lower threshold QX_THL.

[0085] When the process of step S108 is completed, the thermal energy monitoring device 20 proceeds to step S110.

[0086] In step S110, the monitoring unit 203 determines whether or not all of the heat quantities Q1 to Q5 are within the normal range. If all of the heat quantities Q1 to Q5 are within the normal range, the monitoring unit 203 proceeds to step S112, and if at least some of the heat quantities Q1 to Q5 are outside the normal range, the monitoring unit 203 proceeds to step S114.

[0087] In step S112, the monitoring unit 203 transmits data including a monitoring result indicating normality to the monitoring support device 30 via the interface device 25.

[0088] On the other hand, in step S114, the monitoring unit 203 transmits data including the monitoring result indicating the abnormality to the monitoring support device 30 through the interface device 25.

[0089] When the process of step S112 or step S114 is completed, the thermal energy monitoring device 20 ends the process of this flowchart.

[0090] In this way, the thermal energy monitoring device 20 can determine whether the sterilization device 50 is normal or abnormal by monitoring whether or not there is a deviation from the normal range defined by the upper threshold QX_THU and the lower threshold QX_THL for each of the heat quantities Q1 to Q5.

[0091] <Configuration of monitoring support device> The functions of the monitoring support device 30 may be realized by any hardware, or any combination of hardware and software. For example, the hardware configuration of the monitoring support device 30 may be the same as the hardware configuration of the thermal energy monitoring device 20. In the following description of the monitoring support device 30, the reference numerals "21", "21A", "22", "23", "24", "25", "26", and "27" in FIG. 3 may be replaced with "31", "31A", "32", "33", "34", "35", "36", and "37", respectively.

[0092] The monitoring support device 30 includes a drive device 31, an auxiliary storage device 32, a memory device 33, a CPU 34, an interface device 35, a display device 36 (an example of a display unit), and an input device 37, each of which is connected by a bus B.

[0093] As shown in FIG. 1, the monitoring support device 30 includes a database (DB) 301 , a threshold setting unit 302 , an alarm output unit 303 , an analysis data creation unit 304 , and a factor analysis unit 305 .

[0094] The functions of DB301, threshold setting unit 302, alarm output unit 303, analysis data creation unit 304, and factor analysis unit 305 may be realized, for example, by a program installed in auxiliary storage device 32 being loaded into memory device 23 and executed by CPU 34. Data corresponding to DB301 may be stored in auxiliary storage device 32.

[0095] The DB301 is configured as a record group that can be searched according to a predetermined search condition, in a state in which records corresponding to data sequentially received from the thermal energy monitoring device 20 are stored. The records include, for example, information on date and time, measurement data of the measuring device 10, status information of the sterilization device 50 (for example, product type and operation mode type, etc.), calculated values ​​of the amounts of heat Q1 to Q5, and monitoring results (normal or abnormal), etc.

[0096] The DB 301 includes reference data 301A corresponding to record data in which the monitoring result is normal, and abnormality data 301B corresponding to record data in which the monitoring result is abnormal.

[0097] The threshold setting unit 302 (an example of a setting unit) sets the thresholds 202A (upper limit threshold QX_THU and lower limit threshold QX_THL) used in the thermal energy monitoring device 20, based on the reference data 301A included in the DB 301. The details of the threshold setting unit 302 will be described later.

[0098] The warning output unit 303 outputs a warning (alert) to the user when the data sequentially received from the heat energy monitoring device 20 includes a monitoring result indicating an abnormality. Specifically, the warning output unit 303 causes the display device 36 to display a screen (hereinafter, "monitoring screen") indicating that the heat energy monitoring device 20 has output a monitoring result of an abnormality. This allows the user to know that an abnormality has occurred in the sterilization device 50 by visually checking the display device 36. In addition, the warning screen may display time series data of the calorific value QX that deviates from the normal range among the calorific values ​​Q1 to Q5, as well as the upper threshold value QX_THU and the lower threshold value QX_THL. This allows the user to know in which direction and to what extent the target calorific value QX deviates from the predetermined range. In addition, the monitoring screen may display measurement data related to the calorific value QX that deviates from the normal range.

[0099] The analytical data creation unit 304 creates data (hereinafter, "analytical data") for performing a cause analysis of an abnormality corresponding to the abnormality data 301B based on the data in the DB 301, specifically, the reference data 301A and the abnormality data 301B. The analytical data creation unit 304 will be described in detail later.

[0100] The factor analysis unit 305 (an example of an extraction unit) extracts a state of the sterilization apparatus 50 corresponding to a cause of an abnormality, such as deviation of the calorific value QX from the normal range, based on the analysis data created by the analysis data creation unit 304. Specifically, the factor analysis unit 305 extracts a state item corresponding to a cause of an abnormality from among a plurality of state items of the sterilization apparatus 50 represented by each of a plurality of measurement data by the measuring device 10. The state items may include, for example, the above-mentioned steam temperature T1, drainage temperature T2, product inlet temperature T3, product outlet temperature T4, cooling water inlet temperature T5, cooling water outlet temperature T6, etc. In addition, the state items may include, for example, steam pressure P1, drainage pressure P2, steam flow rate F1, drainage flow rate F2, product inlet flow rate F3, product outlet flow rate F4, cooling water inlet flow rate F5, and cooling water outlet flow rate F6, etc. Details of the factor analysis unit 305 will be described later.

[0101] <Details on threshold setting process> Fig. 5 is a flow chart showing an example of a process related to threshold setting by the monitoring support device 30. Fig. 6 is a diagram showing an example (threshold setting input screen 600) of a screen displayed on the display device 36 for the user to input for threshold setting (hereinafter, "threshold setting input screen"). Fig. 7 is a diagram showing an example (threshold final setting screen 700) of a screen displayed on the display device 36 for the user to finally set a threshold based on thresholds calculated as candidates (hereinafter, "threshold final setting screen").

[0102] Execution of the flowchart in FIG. 5 begins when an input for displaying a threshold setting input screen on the display device 36 is accepted via the input device 37, for example.

[0103] As shown in FIG. 5, in step S202, the threshold setting unit 302 receives, via the input device 37, an input of extraction conditions for extracting data to be used for setting a threshold from the reference data 301A of the DB 301.

[0104] For example, as shown in FIG. 6, a threshold setting input screen 600 includes an extraction condition input section 601.

[0105] The extraction condition input section 601 includes a product type condition input section 601A, an operation mode condition input section 601B, a start date and time condition input section 601C, an end date and time condition input section 601D, and an exclusion condition input section 601E.

[0106] The product type condition input section 601A is used by the user to input extraction conditions related to product types. The user operates the product type condition input section 601A via the input device 37 to input extraction conditions related to product types. This enables the threshold setting section 302 to extract records limited by product type, which is one of the static states of the sterilization device 50, from the record group corresponding to the reference data 301A.

[0107] The operation mode condition input unit 601B is used by the user to input extraction conditions related to the operation mode. The user operates the operation mode condition input unit 601B via the input device 37 to input extraction conditions related to the operation mode. This enables the threshold setting unit 302 to extract records limited to the operation mode, which is one of the static states of the sterilization apparatus 50, from the record group corresponding to the reference data 301A.

[0108] The start date and time condition input section 601C is used by the user to input a start date and time condition corresponding to the beginning of the extraction conditions that limit the period. The end date and time condition input section 601D is used by the user to input an end date and time condition corresponding to the end of the extraction conditions that limit the period. The user operates the start date and time condition input section 601C and the end date and time condition input section 601D via the input device 37 to input the extraction conditions that limit the period (the start date and time and the end date and time of the period). This allows the threshold setting section 302 to extract records that are limited to a specific period from the record group that corresponds to the reference data 301A.

[0109] The exclusion condition input unit 601E is used by the user to input conditions (hereinafter, "exclusion conditions") for excluding data (records) that match specific conditions. The user operates the exclusion condition input unit 601E via the input device 37 to input the exclusion conditions. This allows the threshold setting unit 302 to extract records that match the extraction conditions related to the above-mentioned product type, operation mode, and period from the record group corresponding to the reference data 301A by excluding data that match the exclusion conditions.

[0110] The exclusion conditions include, for example, conditions for excluding data for a predetermined period (e.g., several minutes to 10 minutes) after status information (i.e., the static state of the sterilization apparatus 50) such as product type or operation mode is switched. This allows the user to exclude data (records) for a predetermined period after the static state of the sterilization apparatus 50, such as product type or operation mode, is switched from the data used for setting the threshold value. This is because, as described above, immediately after the static state of the sterilization apparatus 50 is switched, it may take some time for the dynamic state of the sterilization apparatus 50 to stabilize.

[0111] Returning to FIG. 5, in step S204, the threshold setting unit 302 receives, via the input device 37, an input of a condition for setting a threshold (hereinafter, a "threshold condition").

[0112] For example, as shown in FIG. 6, a threshold setting input screen 600 includes a threshold condition input section 602.

[0113] The threshold condition input unit 602 is used by the user to input the threshold condition. The user operates the threshold condition input unit 602 via the input device 37 to input the threshold condition. This allows the threshold setting unit 302 to set thresholds (upper limit threshold QX_THU and lower limit threshold QX_THL) that match the threshold condition, based on the records extracted according to the extraction condition input in step S202.

[0114] In this example, the threshold condition is a condition that indicates what percentage of margin should be set for the upper and lower limits of the heat quantity QX of the data extracted according to the extraction condition from the reference data 301A (normal data). In other words, it is a condition that indicates the margin m [%] of the upper threshold QX_THU and the lower threshold QX_THL for the upper and lower limits of the extracted data.

[0115] The processes of steps S202 and S204 may be performed in parallel in response to an operation performed by the user via the input device 37.

[0116] When an operation for requesting calculation of a threshold value is performed via the input device 37 after the input of the extraction conditions and threshold value conditions in steps S202 and S204 is completed, the monitoring support device 30 proceeds to step S206.

[0117] For example, as shown in FIG. 6, a threshold setting input screen 600 includes a calculation request input section 603 .

[0118] The calculation request input unit 603 is used by the user to perform an operation requesting calculation of a threshold value. The user operates the calculation request input unit 603 through the input device 37. As a result, the threshold setting unit 302 proceeds to the process of step S206 in a state in which input to the extraction condition input unit 601 and the threshold condition input unit 602 has been completed.

[0119] 5, in step S206, the threshold setting unit 302 calculates a threshold according to the threshold condition input in step S204, based on the upper and lower limits of the heat quantity QX of the data extracted according to the extraction condition input in step S202. The threshold setting unit 302 calculates the thresholds (upper threshold QX_THU and lower threshold QX_THL) using, for example, the following formulas (11) and (12).

[0120]

number

[0121] The threshold setting unit 302 may display the calculation result of the threshold on a threshold setting input screen 600.

[0122] For example, as shown in FIG. 6, a threshold setting input screen 600 includes a current threshold display section 604 and a threshold calculation result display section 605.

[0123] The currently set thresholds (upper limit threshold QX_THU and lower limit threshold QX_THL) for the amounts of heat Q1 to Q5 are displayed in the current threshold display section 604. This allows the user to check the currently set thresholds (upper limit threshold QX_THU and lower limit threshold QX_THL).

[0124] The newly calculated thresholds (upper threshold QX_THU and lower threshold QX_THL) are displayed in the threshold calculation result display unit 605. This allows the user to confirm the calculation results of the thresholds (upper threshold QX_THU and lower threshold QX_THL) based on the new extracted data. In addition, the threshold calculation result display unit 605 may also display the average value, upper limit, lower limit, etc. of the heat quantity QX of the extracted data.

[0125] Returning to FIG. 5, after the process of step S206, when an input requesting transition to the threshold final setting screen is received via the input device 37, the monitoring support device 30 proceeds to step S208.

[0126] In step S208, the threshold setting unit 302 transitions the display content of the display device 36 from the threshold setting input screen to a threshold final setting screen.

[0127] For example, as shown in FIG. 6, a threshold setting input screen 600 includes a display request input section 606 .

[0128] The display request input unit 606 is used by the user to request a transition to a final threshold setting screen. The user operates the display request input unit 606 via the input device 37. As a result, the threshold setting unit 302 transitions the display content of the display device 36 from the threshold setting input screen 600 to the final threshold setting screen 700, on the premise that the threshold calculation process (step S206) has been completed.

[0129] For example, as shown in FIG. 7, a threshold final setting screen 700 includes a time series display section 701, a frequency distribution display section 702, a target heat quantity selection section 703, a correction request input section 704, and an end request input section 705.

[0130] The data extracted according to the extraction conditions input in step S202 is displayed in a chronological graph in the time series display section 701. In this example, the data extracted according to the extraction conditions is displayed by a solid line, and the data excluded according to the exclusion conditions, i.e., the data for a predetermined period immediately after switching of the status information corresponding to the static state of the sterilization device 50, is displayed by a dotted line.

[0131] An upper threshold line 701A and a lower threshold line 701B corresponding to the upper threshold QX_THU and the lower threshold QX_THL, respectively, are displayed in the time series display section 701. This allows the user to visually confirm the relationship between the time series change of the extracted data and the upper threshold QX_THU and the lower threshold QX_THL.

[0132] In the frequency distribution display section 702, the data extracted in accordance with the extraction conditions input in step S202 is displayed as a frequency distribution for each equally spaced value section.

[0133] An upper threshold line 702A and a lower threshold line 702B corresponding to the upper threshold QX_THU and the lower threshold QX_THL, respectively, are displayed in the frequency distribution display section 702. This allows the user to visually confirm the relationship between the frequency distribution of the extracted data and the upper threshold QX_THU and the lower threshold QX_THL.

[0134] The target calorie selection section 703 is used by the user to select the target calorie QX to be displayed from the calorie amounts Q1 to Q5. The user can operate the target calorie selection section 703 via the input device 37 to switch the target calorie QX to be displayed on the threshold final setting screen.

[0135] The modification request input unit 704 is used for inputting a user request for modification of the calculated thresholds (upper limit threshold QX_THU and lower limit threshold QX_THL). The user operates the modification request input unit 704 through the input device 37. In this case, the threshold setting unit 302 permits modification of the calculated thresholds. Specifically, the threshold setting unit 302 may display an input box in which a threshold value can be directly input on the threshold final setting screen 700. In addition, the threshold setting unit 302 may permit, for example, the upper limit threshold lines 701A, 702A and the lower limit threshold lines 701B, 702B on the threshold final setting screen 700 to be directly moved through the input device 37. For example, the threshold setting unit 302 permits the user to modify the thresholds in a manner of moving the upper limit threshold lines 701A, 702A and the lower limit threshold lines 701B, 702B on the threshold final setting screen 700 using a touch panel implemented on the display device 36.

[0136] The end request input section 705 is used by the user to request completion (end of setting) of threshold setting with the contents displayed on the threshold final setting screen 700. The user operates the end request input section 705 via the input device 37.

[0137] Returning to FIG. 5, when the processing of step S208 is completed, the monitoring support device 30 proceeds to step S210.

[0138] In step S210, the threshold setting unit 302 determines whether or not an input to end the threshold setting (setting completion) has been made through the input device 37 (for example, operation of the end request input unit 705). If an input to end the threshold setting has been made, the threshold setting unit 302 sets and saves the thresholds (upper threshold QX_THU and lower threshold QX_THL) to values ​​corresponding to the display contents of the final threshold setting screen, and ends the processing of this flowchart. On the other hand, if an input requesting a correction of the thresholds (for example, operation of the correction request input unit 704) has been made rather than an input to end the threshold setting, the threshold setting unit 302 proceeds to step S212.

[0139] In step S212, the threshold setting unit 302 modifies the threshold in response to an input from the input device 37.

[0140] When the processing of step S212 is completed, the monitoring support device 30 returns to step S208, and the threshold setting unit 302 corrects the contents of the final threshold setting screen so as to correspond to the corrected threshold, and causes it to be displayed.

[0141] In this way, the threshold setting unit 302 can calculate and set the upper threshold QX_THU and the lower threshold QX_THL from the upper and lower limit values ​​of the heat quantity QX of the data extracted in accordance with the extraction conditions in response to a request from a user.

[0142] <Details of the process for factor analysis> Fig. 8 is a diagram showing an example of an abnormality occurrence history screen (abnormality occurrence history screen 800). Fig. 9 is a diagram showing an outline of a processing flow relating to an abnormality cause analysis by the thermal energy monitoring device 20. Fig. 10 is a diagram showing an example (analysis result screen 1000) of a screen showing the results of the cause analysis processing by the cause analysis unit 305 (hereinafter, "analysis result screen"). Fig. 11 is a diagram showing another example of the analysis result screen (analysis result screen 1100).

[0143] In response to a request from a user via the input device 37, the monitoring support device 30 causes the display device 36 to display an abnormality occurrence history screen showing a history (record) of abnormality occurrences corresponding to deviation of the heat quantity QX from the normal range. The abnormality occurrence history (record) may include, for example, the type of abnormality, the date and time of the abnormality occurrence, the date and time of the abnormality end (return to normal), the product type at the time of the abnormality occurrence, the operation mode at the time of the abnormality occurrence, the calculated values ​​of the heat quantities Q1 to Q5 at the time of the abnormality occurrence, and the like.

[0144] For example, as shown in FIG. 8, an abnormality occurrence history screen 800 is displayed on the display device .

[0145] The abnormality occurrence history screen 800 includes an abnormality type condition input section 801, a start date and time condition input section 802, an end date and time condition input section 803, a product type condition input section 804, an operation mode condition input section 805, a display request input section 806, and an abnormality occurrence history display section 810.

[0146] The abnormality type condition input unit 801 is used by the user to input conditions related to the type of abnormality when extracting the history of abnormality occurrence from the abnormality-state data 301B. The user operates the abnormality type condition input unit 801 via the input device 37 to input conditions related to the type of abnormality.

[0147] The start date and time condition input section 802 is used by the user to input a start date and time condition that corresponds to the start of a period when an abnormality occurrence history is extracted from the abnormality data 301 B. The user operates the start date and time condition input section 802 via the input device 37 to input a condition related to the start date and time.

[0148] The end date and time condition input section 803 is used by the user to input a condition for an end date and time corresponding to the end of a period when an abnormality occurrence history is extracted from the abnormality-time data 301 B. The user operates the end date and time condition input section 803 via the input device 37 to input a condition related to the end date and time.

[0149] The product type condition input section 804 is used by the user to input conditions related to the product type at the time of an abnormality occurrence when extracting the abnormality occurrence history from the abnormality data 301 B. The user operates the product type condition input section 804 via the input device 37 to input the conditions related to the product type.

[0150] The operation mode condition input unit 805 is used by the user to input conditions related to the operation mode at the time of an abnormality occurrence when extracting the abnormality occurrence history from the abnormality data 301 B. The user operates the operation mode condition input unit 805 via the input device 37 to input the conditions related to the operation mode.

[0151] The display request input unit 806 is used by the user to input a display request for the abnormality occurrence history according to the conditions input in the condition input units 801 to 805. The user operates the display request input unit 806 via the input device 37 to input the display request for the abnormality occurrence history.

[0152] In the abnormality occurrence history display section 810, abnormality occurrence history (records) according to the conditions inputted in the condition input sections 801 to 805 are displayed in response to the operation of the display request input section 806, i.e., the display request. The user can select any one (one row) from the abnormality occurrence history records corresponding to each example in the figure through the input device 37. This causes the monitoring support device 30 to start processing related to the analysis of the cause of the abnormality occurrence corresponding to the selected abnormality occurrence history record.

[0153] For example, as shown in FIG. 9, first, the analysis data creation unit 304 executes a data creation process to create analysis data 304A based on the reference data 301A and the abnormality data 301B. Specifically, the analysis data creation unit 304 creates the analysis data 304A from time series data of the dynamic state of the sterilization device 50 at the time of abnormality occurrence corresponding to the record selected on the abnormality occurrence history screen and at normal times. The time series data of the dynamic state corresponds to, for example, time series data of the measurement data (measurement value) of the measurement device 10. In addition, it is preferable that the time series data of the dynamic state at normal times is, for example, time series data of the dynamic state included in the reference data 301A (extracted data) used for setting the upper threshold QX_THU and the lower threshold QX_THL by the threshold setting unit 302. This is because data with consistency of the normal / abnormal judgment criteria should be compared.

[0154] For example, the analysis data 304A may be data in a table format (matrix format) such as a CSV (Comma Separated Value) file. Specifically, the analysis data 304A may be in a format in which records with different dates and times (times) are arranged in the row direction, and multiple status items representing dynamic states and multiple data items including items representing normal / abnormal states are arranged in the column direction.

[0155] When the analysis data 304A is output from the analysis data creation unit 304, the cause analysis unit 305 performs a cause analysis process of the abnormality occurrence corresponding to the abnormality occurrence history record selected on the abnormality occurrence history screen, using the analysis data 304A. Specifically, the cause analysis unit 305 uses the analysis data 304A to extract a status item corresponding to the cause of the abnormality occurrence from a plurality of status items representing the dynamic status of the sterilization device 50.

[0156] For example, the factor analysis unit 305 uses two factor analysis methods, correlation analysis and decision tree analysis, based on the analysis data 304A to extract status items corresponding to the cause of abnormality occurrence from multiple status items representing the dynamic status of the sterilization apparatus 50. Specifically, the factor analysis unit 305 may calculate a correlation coefficient and variable importance between data (measurement data) of each of the multiple status items and data representing abnormality or normality (for example, data in which abnormality or normality is distinguished by "0" or "1").

[0157] In correlation analysis, the correlation coefficient is calculated in the range of -1 to +1, and the larger the absolute value, the higher the correlation (linear relationship) between the target status item and abnormal / normal status, i.e., the higher the degree to which the target status item represents the cause of abnormality. Also, in decision tree analysis, variable importance is calculated in the range of 0 to 1, and indicates the importance of the target status item as a cause of abnormality.

[0158] The factor analysis unit 305 may calculate a correlation coefficient between each of the multiple status items and data indicating whether the status is normal or abnormal, and extract a status item having a relatively large absolute value of the correlation coefficient from among the multiple status items as a cause (candidate) of the abnormality. For example, the factor analysis unit 305 may extract a status item having an absolute value of the correlation coefficient equal to or greater than a predetermined threshold from among the multiple status items, or a status item having a correlation coefficient that is within a predetermined number (e.g., three) of the largest absolute values ​​of the correlation coefficient from among the multiple status items.

[0159] Similarly, the factor analysis unit 305 may calculate the variable importance of each of the multiple status items with respect to data indicating whether the status is normal or abnormal, and extract a status item with a relatively high variable importance from among the multiple status items as a cause (candidate) of the occurrence of the abnormality. For example, the factor analysis unit 305 may extract a status item with a variable importance equal to or greater than a predetermined threshold from among the multiple status items, or a status item with a variable importance within a predetermined number (e.g., three) of the highest from among the multiple status items.

[0160] The factor analysis unit 305 outputs analysis result data 305A indicating the result of the factor analysis process. The analysis result data 305A includes, for example, the calculated values ​​of the correlation coefficient and importance coefficient between abnormality / normality for each of a plurality of status items. The analysis result data 305A may also include, for example, information on status items with relatively large correlation coefficients with abnormality / normality and status items with relatively large importance coefficients as candidates for the cause of the abnormality.

[0161] Furthermore, the factor analysis section 305 may cause the display device 36 to display a screen (analysis result screen) showing the result of the factor analysis process based on the analysis result data 305A.

[0162] For example, as shown in FIG. 10, the factor analysis section 305 may cause the display device 36 to display an analysis result screen 1000.

[0163] In addition, the "Tag name" in Fig. 10 corresponds to the type of status item. The same applies to Fig. 11 below.

[0164] The analysis result screen 1000 lists the correlation coefficients (absolute values) and variable importances calculated by the correlation analysis and decision tree analysis from top to bottom in descending order of status item ("Tag name").

[0165] Note that status items for which both the correlation coefficient and the variable importance are calculated as zero (0) are not displayed on the analysis result screen 1000. Therefore, in the decision tree analysis, only the variable importance of three status items is displayed.

[0166] Also, for example, as shown in FIG. 11, the factor analysis section 305 may cause the display device 36 to display an analysis result screen 1100.

[0167] The analysis result screen 1100 displays a scatter diagram of time-series data of the top three status items in terms of correlation coefficient (absolute value) and variable importance calculated by correlation analysis and decision tree analysis. Specifically, the analysis result screen 1100 displays a scatter diagram showing the relationship between the top three status items in terms of correlation coefficient (absolute value) and variable importance, and the amount of heat QX (in this example, the amount of coolant waste heat Q4) that deviates from the normal range. At this time, each plot of the scatter diagram is displayed in a manner that allows distinction between normal and abnormal conditions. For example, each plot in the scatter section may be distinguished by color or shape depending on whether it is normal or abnormal.

[0168] This allows the user to, for example, identify the cause of the abnormality from the status items (in this example, Tag1, Tag30, etc.) that are displayed at the top of both the correlation coefficient and the importance coefficient, and take measures to recover from the abnormality.

[0169] In this way, when an abnormality occurs in which any of the heat quantities QX of Q1 to Q5 deviates from the normal range, the monitoring support device 30 can extract a status item corresponding to the cause of the abnormality from multiple status items that represent the dynamic state of the sterilization device 50 before it is reduced to the target heat quantity QX. Furthermore, by applying two factor analysis methods (two indexes), namely correlation analysis and decision tree analysis, the monitoring support device 30 can extract a status item corresponding to the cause, regardless of whether the monitored device (sterilization device 50) is a linear device or a nonlinear device.

[0170] [Other embodiments] Next, another embodiment will be described.

[0171] The above-described embodiment may be modified or altered as appropriate.

[0172] For example, in the above embodiment, when it is not the monitoring period (NO in step S106 in FIG. 4), the thermal energy monitoring device 20 may transmit data including a monitoring result indicating that it is outside the monitoring period to the monitoring support device 30. Also, the process of step S106 in FIG. 4 may be omitted.

[0173] Furthermore, for example, in the above-described embodiments and modifications, the heat balance calculation unit 201 may use an empirical formula based on empirical rules obtained through experiments, simulations, etc., instead of the logical formulas or approximation formulas based on logical formulas such as those in (2) to (9) above. In this case, the measurement data used in the empirical formula may include measurement data of measurement targets other than the temperature, pressure, and flow rate inside the sterilization device 50.

[0174] Also, for example, in the above-described embodiment and modified examples, the function of the alarm output unit 303 may be provided in the thermal energy monitoring device 20 instead of or in addition to the monitoring assistance device 30. Also, the alarm output unit 303 may transmit an alarm signal to a portable terminal device carried by the user, such as a smartphone or a tablet terminal, and output an alarm (alert) to the user through the portable terminal device. In this case, the alarm screen may be displayed on the portable terminal device carried by the user.

[0175] Also, for example, in the above-described embodiment and examples of modifications and variations, some or all of the functions of the monitoring support device 30 may be integrated into the thermal energy monitoring device 20. Also, some of the functions of the monitoring support device 30 may be transferred to another device. That is, the functions of the monitoring support device 30 may be shared and realized by a plurality of devices. For example, the monitoring standard setting function and the factor analysis function of the monitoring support device 30 may be shared and realized by different devices.

[0176] Also, for example, in the above-mentioned embodiment and modified examples, the threshold setting unit 302 may set a threshold for the target calorific value QX using all of the data of the reference data 301A instead of the partial data extracted from the reference data 301A. Also, the threshold setting unit 302 may set a threshold based on an average value instead of the upper and lower limits of all or partial data of the reference data 301A for the target calorific value QX.

[0177] Also, for example, in the above-mentioned embodiments and modifications, the factor analysis unit 305 may use three or more types of factor analysis methods to extract status items of the sterilization device 50 corresponding to the cause of deviation of the target calorific value QX from the normal range. Also, the factor analysis unit 305 may use another factor analysis method instead of or in addition to at least one of the correlation analysis and the decision tree analysis to extract status items of the sterilization device 50 corresponding to the cause of deviation of the target calorific value QX from the normal range.

[0178] Furthermore, for example, in the above-described embodiments and modified or altered examples, the correlation coefficient (absolute value) and variable importance calculated by the correlation analysis and decision tree analysis may be displayed on the analysis result screen of the display device 36 in both list form and scatter plot form.

[0179] Furthermore, for example, in the above-described embodiments and examples of variations and modifications, the monitored device of the thermal energy monitoring system 1 (thermal energy monitoring device 20) may be any device other than the sterilization device 50, so long as it is a device that generates a heat balance (heat input and output) including the generation and absorption of heat.

[0180] [Effect] Next, the operation of the thermal energy monitoring system 1 according to this embodiment will be described.

[0181] For example, when monitoring status data (measurement data) of a monitored device as in Patent Document 1 mentioned above, if the types of status data to be monitored are relatively large, it becomes necessary to prepare criteria for determining abnormalities for each type, which can result in a lot of work.

[0182] On the other hand, it is also possible to reduce multiple types of state data to fewer variables, as in the above-mentioned Patent Document 2 and the method of Multivariate Statistical Process Control (MSPC).

[0183] However, although these methods reduce the effort required to prepare criteria for anomaly determination, they may not be able to easily determine which type of status data corresponds to which status item when an anomaly occurs. Also, while these methods are effective when the monitored device can be considered linear, they may not be applicable when the device is nonlinear, or even if they are applicable, they may take a long time to estimate (identify) the cause.

[0184] In contrast, in this embodiment, the thermal energy monitoring device 20 includes a heat balance calculation unit 201 and a monitoring unit 203. Specifically, the heat balance calculation unit 201 acquires data related to the state of the monitored device, and calculates multiple types of thermal energy (e.g., heat amounts Q1 to Q5) that constitute the heat balance of the monitored device based on the data. Then, the monitoring unit 203 monitors, for each of the multiple types of thermal energy calculated by the heat balance calculation unit 201, whether or not the target type of thermal energy deviates from a normal range defined by an upper threshold and a lower threshold.

[0185] As a result, the thermal energy monitoring device 20 can convert the target to be monitored into data of many status items (e.g., measurement data) related to the monitored device, and reduce it to multiple types of thermal energy (e.g., five types) that make up the heat balance. Therefore, the effort required to prepare criteria for abnormality determination can be relatively reduced. In addition, by using data of multiple types of thermal energy that make up the heat balance, the thermal energy monitoring device 20 can be applied to both linear and nonlinear monitored devices, and can estimate (identify) the causes relatively easily.

[0186] In addition, in this embodiment, data regarding the state of the monitored device may include data regarding the dynamic state, including the temperature, pressure, and flow rate, of the monitored device, and data regarding the static state, including the operating state of the monitored device.

[0187] In this way, the thermal energy monitoring device 20 can calculate each of the multiple types of thermal energy that constitute the heat balance of the monitored device based on data on multiple status items that correspond to the dynamic status of the monitored device. Also, the thermal energy monitoring device 20 can monitor for deviation from the normal range, taking into account the static status.

[0188] Furthermore, in this embodiment, the monitoring unit 203 may set at least one of the upper threshold and the lower threshold to be different for each type of static state of the monitored device (for example, type of operation mode or type of product).

[0189] This allows the thermal energy monitoring device 20 to specifically monitor for deviations from the normal range, taking into account static conditions.

[0190] In this embodiment, the monitoring unit 203 suspends monitoring of the multiple types of thermal energy when the static state of the monitored device is switched, and may resume monitoring of the multiple types of thermal energy after a predetermined time has elapsed after the static state of the monitored device is switched.

[0191] This allows the thermal energy monitoring device 20 to appropriately monitor a plurality of types of thermal energy in accordance with the change in the static state of the monitored device. When the static state of the monitored device changes, the heat balance of the monitored device changes, and it takes time for the change to stabilize.

[0192] In the present embodiment, the monitoring support device 30 includes a threshold setting unit 302. Specifically, the threshold setting unit 302 may set an upper threshold and a lower threshold based on time-series data of a plurality of types of thermal energy calculated by the heat balance calculation unit 201.

[0193] As a result, the monitoring support device 30 can set the upper threshold and the lower threshold, for example, based on historical data of the target's thermal energy under normal conditions (e.g., reference data 301A), i.e., data of the target's thermal energy under normal conditions accumulated in chronological order.

[0194] In addition, in this embodiment, the threshold setting unit 302 may set an upper threshold and a lower threshold for a target type of thermal energy among the multiple types of thermal energy, based on an upper limit value and a lower limit value or an average value of the time-series data.

[0195] This allows the monitoring support device 30 to specifically set the upper and lower thresholds based on the history data (time-series data) of the thermal energy of the target under normal conditions.

[0196] In addition, in this embodiment, the threshold setting unit 302 may extract partial data that meets extraction conditions including at least one of a condition regarding the type of static state of the monitored device and a condition regarding time from the entire time series data for a target type of thermal energy among the multiple types of thermal energy, and set an upper threshold and a lower threshold based on the extracted partial data.

[0197] As a result, the monitoring support device 30 can limit the target thermal energy history data in normal times to partial data that meets the extraction conditions, and set the upper and lower thresholds based on the limited partial data. Therefore, the monitoring support device 30 can select more appropriate data as a basis for setting the upper and lower thresholds, for example. Therefore, the monitoring support device 30 can more appropriately set the upper and lower thresholds.

[0198] In the present embodiment, the monitoring support device 30 includes a display device 36. Specifically, the display device 36 may display at least one of a time series graph, a frequency distribution graph, and a scatter diagram graph of a target type of thermal energy among the multiple types of thermal energy, as well as candidates for upper and lower thresholds calculated by the threshold setting unit 302 based on the time series data of the target type of thermal energy. The display device 36 may display an input object (for example, upper threshold lines 701A, 702A and lower threshold lines 701B, 702B, etc. that can be operated by a touch panel as the input device 37) that accepts input from a user to correct the candidates for the upper and lower thresholds.

[0199] This allows the user to visually check on the screen the relationship between the target thermal energy history data, which is the basis for calculating the upper and lower thresholds, and the upper and lower thresholds. In addition, the user can modify the candidates for the upper and lower thresholds on the screen. Therefore, the monitoring support device 30 can improve the convenience for the user.

[0200] Moreover, in this embodiment, the monitoring support device 30 includes a factor analysis unit 305. Specifically, when the thermal energy monitoring device 20 detects a deviation from a normal range of a predetermined thermal energy among a plurality of types of thermal energy, the factor analysis unit 305 may extract a status item representing a factor of the deviation from the normal range of the predetermined thermal energy from among a plurality of status items representing the status of the monitored device.

[0201] As a result, when the predetermined thermal energy deviates from the normal range, the monitoring support device 30 can identify (estimate) the status item of the monitored device that corresponds to the cause of the deviation.

[0202] In addition, in this embodiment, the factor analysis unit 305 may extract, from the multiple status items, a status item that indicates a factor of a deviation of the specified thermal energy from the normal range, using multiple factor analysis methods including at least one of correlation analysis and decision tree analysis, based on the time series data of the multiple status items when a deviation of the specified thermal energy from the normal range is detected and the time series data of the multiple status items when there is no deviation of the specified thermal energy from the normal range.

[0203] In this way, the monitoring support device 30 can specifically identify (estimate) the state items of the monitored device that correspond to the cause of the abnormality of deviation of the predetermined thermal energy from the normal range. Furthermore, by using a plurality of factor analysis methods, the monitoring support device 30 can perform factor estimation regardless of whether the monitored device is a linear device or a nonlinear device, and can improve the accuracy of the factor estimation.

[0204] Moreover, in this embodiment, the monitoring support device 30 includes a display device 36 that displays the extraction results of the factor analysis unit 305. Specifically, the display device 36 may display, for each of a plurality of status items, a degree of representing the factor of deviation of a predetermined thermal energy from a normal range (for example, a correlation coefficient in a correlation analysis or a variable importance in a decision tree analysis) as a list, or as a scatter plot for time-series data of the predetermined thermal energy.

[0205] This allows the user to visually confirm the degree of the cause of the deviation from the normal range of the predetermined thermal energy, and from that degree, to grasp the status item of the monitored device that corresponds to the cause.

[0206] Although the embodiments have been described in detail above, the present disclosure is not limited to such specific embodiments, and various modifications and variations are possible within the scope of the gist described in the claims. [Explanation of symbols]

[0207] 1. Thermal Energy Monitoring System 10. Measurement Equipment 11 Temperature Sensor 12 Pressure Sensor 13 Flow Sensor 20 Thermal energy monitoring device (monitoring device) 21 Drive device 21A Recording media 22 Auxiliary storage 23 Memory Device 24 CPU 25 Interface Device 26 Display device 27 Input Devices 30 Monitoring support device (threshold setting device, factor analysis device) 36 Display device (display section) 40 Production Management System 50 Sterilization equipment (monitored equipment) 51 Product Passage Path 52 High-temperature water circulation route 52A Pump 53 Steam inflow path 54 Drainage route 55 Cooling water passage 56 Heating section 57 Cooling section 201 Heat balance calculation unit (heat energy calculation unit) 202 Storage section 202A Threshold 203 Monitoring Department 301 Database 302 Threshold setting unit (setting unit) 303 Alarm output unit 304 Analysis Data Creation Department 305 Factor Analysis Unit (Extraction Unit) 600 Threshold setting input screen 700 Threshold final setting screen 800 Abnormality history screen 1000,1100 analysis result screen

Claims

1. A thermal energy calculation unit that acquires data regarding a state of a monitored device and calculates a plurality of types of thermal energy that constitute an entire heat balance in the monitored device based on the acquired data; a monitoring unit that monitors whether or not the heat energy of a target type deviates from a predetermined range defined by an upper threshold and a lower threshold for each of the plurality of types of heat energy calculated by the heat energy calculation unit, The data on the state of the monitored device includes data on dynamic states of the monitored device, including temperatures, pressures, and flow rates, and data on static states of the monitored device, including operating states; the monitoring unit varies at least one of the upper limit threshold and the lower limit threshold for each type of static state of the monitoring target device; monitoring equipment.

2. the monitoring unit suspends monitoring of the plurality of types of thermal energy when a static state of the monitored device is switched, and resumes monitoring of the plurality of types of thermal energy after a predetermined time has elapsed since the static state of the monitored device is switched. The monitoring device according to claim 1.

3. 3. A threshold setting device for setting the upper limit threshold and the lower limit threshold used in the monitoring device according to claim 1, a setting unit that sets the upper limit threshold and the lower limit threshold based on time series data of the plurality of types of thermal energy calculated by the thermal energy calculation unit, Threshold setting device.

4. the setting unit sets the upper limit threshold and the lower limit threshold for a target type of thermal energy among the plurality of types of thermal energy, based on an upper limit value and a lower limit value or an average value of time-series data; The threshold setting device according to claim 3 .

5. the setting unit extracts partial data that meets extraction conditions including at least one of a condition related to a type of static state of the monitored device and a condition related to time from the entire time-series data for a target type of thermal energy among the multiple types of thermal energy, and sets the upper limit threshold and the lower limit threshold based on the extracted partial data.

5. The threshold setting device according to claim 3 or 4.

6. a display unit that displays at least one of a time series graph, a frequency distribution graph, and a scatter plot graph of a target type of thermal energy among the plurality of types of thermal energy, and candidates for the upper limit threshold and the lower limit threshold calculated by the setting unit based on the time series data of the target type of thermal energy, and displays an input object that receives an input from a user to correct the candidates; A threshold setting device according to any one of claims 3 to 5.

7. an extraction unit configured to extract, when a deviation of a predetermined thermal energy from the predetermined range is detected by the monitoring device according to claim 1 or 2, a status item representing a cause of the deviation of the predetermined thermal energy from the predetermined range from a plurality of status items representing a status of the monitored device related to the predetermined thermal energy; Factor analysis device.

8. the extraction unit extracts, from the plurality of status items, a status item representing a cause of deviation of the predetermined thermal energy from the predetermined range, using a plurality of factor analysis methods including at least one of correlation analysis and decision tree analysis, based on time series data of the plurality of status items when a deviation of the predetermined thermal energy from the predetermined range is detected and time series data of the plurality of status items when there is no deviation of the predetermined thermal energy from the predetermined range; The factor analysis device according to claim 7.

9. a display unit that displays an extraction result of the extraction unit, the display unit displays, for each of the plurality of status items, a degree representing a factor of deviation of the predetermined thermal energy from the predetermined range as a list or as a scatter diagram for time-series data of the predetermined thermal energy. The factor analysis device according to claim 7 or 8.

10. A monitoring method executed by a monitoring device, comprising: a thermal energy calculation step of acquiring data on a state of the monitored device and calculating a plurality of types of thermal energy constituting an entire heat balance in the monitored device based on the acquired data; a monitoring step of monitoring whether or not the heat energy of the target type deviates from a predetermined range defined by an upper threshold and a lower threshold for each of the plurality of types of heat energy calculated in the heat energy calculation step, The data on the state of the monitored device includes data on dynamic states of the monitored device, including temperatures, pressures, and flow rates, and data on static states of the monitored device, including operating states; In the monitoring step, at least one of the upper limit threshold and the lower limit threshold is made different for each type of static state of the monitoring target device. Monitoring method.

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