Diagnostic device, diagnostic method, and diagnostic program

Abstract

To make it possible to take a quick countermeasure to a trouble.SOLUTION: A diagnostic device includes a diagnostic unit which specifies a trouble factor and a trouble countermeasure of a diagnosis object field device on the basis of a diagnosis database which manages an operation history, trouble factors, and trouble countermeasures in association with each other, and an operation history of a diagnosis object field device.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a diagnostic apparatus, a diagnostic method, and a diagnostic program.

Background Art

[0002] In field devices, it is known to perform operations such as parameter setting and adjustment, and to record operation histories (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When a trouble occurs in a field device, it is necessary to identify the cause of the trouble and the countermeasure for the trouble. Conventionally, an engineer with specialized knowledge has performed reproduction tests and data analysis work by referring to past trouble cases. Since the work takes time, there is a problem that it is difficult to take prompt trouble countermeasures.

[0005] One aspect of the present disclosure enables prompt trouble countermeasures.

Means for Solving the Problems

[0006] A diagnostic apparatus according to one aspect includes a diagnostic database that manages by associating an operation history, a trouble cause, and a trouble countermeasure of a reference field device, and a diagnostic unit that identifies a trouble cause and a trouble countermeasure of a diagnostic target field device based on the operation history of the diagnostic target field device.

[0007] One aspect of the diagnostic method includes identifying the trouble factors and troubleshooting measures for a field device under diagnosis based on a diagnostic database that manages the operation history, trouble factors, and troubleshooting measures of a reference field device in association with the operation history of the field device under diagnosis.

[0008] The diagnostic program for one aspect causes the computer to execute a process to identify the trouble cause and trouble countermeasures for the field device being diagnosed, based on a diagnostic database that manages the operation history, trouble cause, and trouble countermeasures of a reference field device in association with the operation history of the field device being diagnosed. [Effects of the Invention]

[0009] According to the present invention, it becomes possible to quickly address problems. [Brief explanation of the drawing]

[0010] [Figure 1] This figure shows an example of the schematic configuration of the diagnostic system according to the embodiment. [Figure 2] This figure shows an example of a diagnostic database. [Figure 3] This figure shows an example of data from a field device being diagnosed. [Figure 4] This figure shows an example of data from a field device being diagnosed. [Figure 5] This flowchart shows examples of the processes (diagnostic methods) performed in relation to the diagnosis. [Figure 6] This figure shows an example of a hardware configuration. [Modes for carrying out the invention]

[0011] The embodiments will be described below with reference to the drawings. The same elements will be denoted by the same reference numerals, and redundant descriptions will be omitted as appropriate.

[0012] Figure 1 shows an example of a schematic configuration of a diagnostic system according to an embodiment. The diagnostic system 100 includes a field device 1, an external circuit 2, a portable operating device 3, a management device 4, and a diagnostic device 5.

[0013] Field device 1 is a measuring instrument installed and used in a field such as a plant or factory, and more specifically, it is a transmitter that transmits a signal indicating the measurement result. Examples of transmitters include pressure transmitters, temperature transmitters, flow rate transmitters, etc. Pressure may be understood to include differential pressure, and a pressure transmitter may be a differential pressure transmitter. The field device 1 illustrated in Figure 1 is a two-wire transmitter and is used in connection with an external circuit 2.

[0014] Multiple field devices 1 exist, and Figure 1 illustrates three field devices 1. To distinguish each field device 1, they are referred to as field device 1-1, field device 1-2, and field device 1-3. When no particular distinction is made, they are simply called field device 1.

[0015] Field device 1 includes a sensor 11, a calculation / operation management unit 12, a DA converter 13, an output circuit 14, a communication IF 15, and an operation switch 16.

[0016] Sensor 11 outputs sensor values. Sensor values ​​are voltage values, current values, etc., that represent the physical quantities (pressure, temperature, flow rate, etc.) that the field device 2 is intended to measure. If the field device 1 is a pressure transmitter, sensor 11 is a pressure sensor, and more specifically, it is a pressure-receiving part (e.g., a diaphragm). If the field device 1 is a temperature transmitter, then a temperature sensor corresponds to sensor 11, and if it is a flow rate transmitter, then a flow rate sensor corresponds to sensor 11.

[0017] The calculation and operation management unit 12 acquires the sensor values output by the sensor 11. The acquisition of the sensor values may be performed periodically or at any specified timing. In the example shown in FIG. 1, the calculation and operation management unit 12 includes a microprocessor 121 and a memory 123. Some processes performed by the microprocessor 121 will be described.

[0018] The microprocessor 121 executes calculations (computations) for converting the sensor values into measured values. The measured values are the physical quantities for the above-described measurement purposes, that is, pressure values, differential pressure values, temperature values, flow rate values, and the like. The method for converting the sensor values into measured values is not particularly limited. For example, an algorithm for calculating the measured value from the sensor value may be used, or a table associating the sensor value and the measured value may be referred to. The microprocessor 121 generates a digital signal indicating the measured value obtained by the calculation and outputs it to the DA converter 13.

[0019] Correction may be applied to the calculation of the measured value by the above-described microprocessor 121. An example of the correction is zero adjustment. The measured value obtained by the calculation is corrected so that the measured value becomes zero when there is no input to the sensor 11 of the field device 1. The correction amount for making the measured value zero is also referred to as the zero adjustment amount. The required zero adjustment amount may change with the operating time of the field device 1. For example, as the operating time of the field device 1 becomes longer, the required zero adjustment amount also becomes larger.

[0020] The microprocessor 121 diagnoses the self-diagnosis of the field device 1, more specifically, whether the state (device state) of the field device 1 is in a normal state or an abnormal state. For example, when the sensor value or the measured value is within a predetermined range (within the normal range), the microprocessor 121 diagnoses that the field device 1 is in a normal state, and when the sensor value or the measured value is outside that range (outside the normal range), the microprocessor 121 diagnoses that the field device 1 is in an abnormal state.

[0021] The microprocessor 121 manages the operation of the field device 1. The operation of the field device 1 includes the adjustment of the field device 1. The adjustment is performed, for example, by setting or changing parameters that define the operation of the field device 1. An example of a specific adjustment is the zero adjustment described above. As will be described later, the operation of the field device 1 is performed using the operation switch 16, the portable operation device 3, or the management device 4.

[0022] The microprocessor 121 manages the operations actually performed on the field device 1. A functional block provided by the microprocessor 121 regarding management is referred to as an operation detection unit 122 and is illustrated.

[0023] The operation detection unit 122 detects an operation performed on the field device 1 and stores the history of that operation in the memory 123 as the operation history 126. If there is already a stored operation history 126, the operation history 126 may be updated. The operation history 126 is data that associates the operation time, operation content, etc. The operation content includes the operation amount such as the zero adjustment amount described above. Also, in this embodiment, the operation history 126 also includes the operation time of the field device 1. The operation time indicates, for example, the time (length of the period) from the start of operation of the field device 1 to the recording time of the operation history 126.

[0024] The memory 123 stores data used by the arithmetic and operation management unit 12. Examples of data stored in the memory 123 include basic data 124, parameters 125, and operation history 126. Since the operation history 126 has been described above, the basic data 124 and the parameters 125 will be described.

[0025] Basic data 124 is unique data for field device 1. Examples of basic data 124 include device ID (Identifier), device type, device tag name, and vendor name. The device ID is an identifier that uniquely identifies field device 1. The device type indicates the type of field device 1, such as a pressure transmitter, temperature transmitter, or flow transmitter. The device tag is identification data for field device 1, such as one set to be easily readable by an operator. The vendor name indicates the vendor of that field device 1.

[0026] Parameter 125 is set for field device 1 and defines, for example, the operation of field device 1. Examples of parameter 125 include the period of calculation of measured values ​​(measurement period), the unit of display of measured values, and the device status of field device 1 obtained by self-diagnosis.

[0027] The DA converter 13 converts the digital signal (a signal indicating a measurement value) from the microprocessor 121 into an analog signal and outputs it to the output circuit 14.

[0028] The output circuit 14 is connected between the output circuit 14 and the external circuit 2. The output circuit 14 converts the analog signal from the DA converter 13 into a current signal and controls the external circuit 2 and the output circuit 14 so that the current signal flows through them. The current signal appears in the external circuit 2 as a signal indicating a measurement, for example, a current signal whose current value changes within the range of 4mA to 20mA depending on the magnitude of the measurement.

[0029] External circuit 2 is described here. External circuit 2 is connected to the corresponding field device 1. There are multiple external circuits 2 corresponding to multiple field devices 1, and Figure 1 shows examples of external circuits 2-1 to 2-3 corresponding to field devices 1-1 to 1-3. Unless otherwise specified, these are simply referred to as external circuit 2.

[0030] External circuit 2 includes a transmission line 21, a DC power supply 22, and a resistor 23. The transmission line 21 is a pair of transmission lines 21 connected to the output circuit 14 of field device 1. The DC power supply 22 and the resistor 23 are connected in series between the pair of transmission lines 21.

[0031] When the aforementioned current signal flows through the external circuit 2, a voltage (potential difference) of a magnitude corresponding to the magnitude of the current signal is generated across the ends of the resistor 23, that is, between the pair of transmission lines 21. By detecting this voltage, the measurement value obtained by the field device 1 is acquired. In this way, the measurement value obtained by the field device 1 is transmitted from the field device 1 to the outside.

[0032] Returning to the description of field device 1, the communication IF15 is a communication interface connected to the transmission line 21 of the external circuit 2. The communication IF15 uses the transmission line 21 of the external circuit 2 as a communication line to communicate with external devices of field device 1, in this example, the portable operating device 3 and the management device 4.

[0033] The operating switch 16 is used to operate the field device 1. For example, the operating switch 16 has various switches corresponding to the operation of the field device 1. By switching the switches, the corresponding operation is performed on the field device 1.

[0034] A portable operating device 3 is also used to operate the field device 1. When in use, the portable operating device 3 is connected to the transmission line 21 of the external circuit 2 and communicates with the communication IF 15 of the field device 1. For example, the portable operating device 3 sends an operation request (such as a command to instruct operation) to the communication IF 15 of the field device 1. In the field device 1, the microprocessor 121 operates the field device 1 according to the operation request received by the communication IF 15.

[0035] The management device 4 is used to manage the field device 1, and this management includes operating the field device 1. The management device 4 includes a field device communication unit 41, a device data management unit 42, a device data storage unit 43, a user interface unit 44, and a work report creation unit 45.

[0036] The field device communication unit 41 is connected to the transmission lines 21 of each of the multiple external circuits 2, and communicates with the communication IF 15 of each of the multiple field devices 1 by using the transmission lines 21 as communication lines.

[0037] The device data management unit 42 controls the entire management device 4 by controlling other elements of the management device 4. For example, the device data management unit 42 controls the field device communication unit 41 to acquire (collect) data from each field device 1. Examples of acquired data include basic data 124, parameters 125, and operation history 126 stored in the memory 123 of each field device 1. The device data management unit 42 also controls the field device communication unit 41 to operate each field device 1. Operation may be performed by transmitting operation requests, similar to the portable operating device 3.

[0038] The equipment data storage unit 43 is a database that organizes the data of the field equipment 1 acquired by the equipment data management unit 42 and stores and manages it as equipment data 431. In the example shown in Figure 1, equipment data 431 is managed for each field equipment 1, and each piece of equipment data 431 is associated with the basic data 124, parameters 125, operation history 126, and attached data 127 of the corresponding field equipment 1. The attached data 127 is additional data (memos, images, etc.) arbitrarily created by the operator regarding that field equipment 1.

[0039] The user interface unit 44 displays device data 431 and accepts operations for each field device 1. In the example shown in Figure 1, the user interface unit 44 includes a display setting unit 441 for connected devices and a display setting unit 442 for stored device data. The display setting unit 441 for connected devices displays data acquired from a field device 1 that is connected (communication is being established) and accepts operations for that field device 1. The display setting unit 442 for stored device data displays device data 431 of any field device 1 stored in the device data storage unit 43 and accepts operations for that field device 1.

[0040] The work report creation unit 45 generates a work report that describes at least a portion of the equipment data 431 according to a predetermined format (template). For example, by generating work reports for both before and after the operation of field equipment 1, the data of field equipment 1 before and after the operation can be recorded in report form.

[0041] Before describing the diagnostic device 5, let's discuss the challenges of the conventional technology. Field devices 1 may experience problems (abnormal conditions). Conventionally, engineers with specialized knowledge would perform diagnostic work to identify the cause of the problem and determine appropriate countermeasures. Specifically, engineers would use a portable operating device 3 or management device 4 to acquire data such as the operation history 126 of the field device 1, and perform diagnostic work such as reproduction tests and data analysis, referring to cases of other field devices 1 that had experienced problems in the past. After such diagnostic work, the cause of the problem and countermeasures would be identified, and then the countermeasures would be provided to the user of the field device 1. A challenge is that rapid countermeasures are difficult because a lot of time is required for the diagnostic work.

[0042] According to this embodiment, as will be explained later, the diagnostic work of the field device 1, including the identification of trouble causes and trouble countermeasures, is automated by the diagnostic device 5, thereby enabling rapid trouble countermeasures.

[0043] Specifically, the diagnostic device 5 diagnoses a target field device 1 from among multiple field devices 1. The target field device 1 is also referred to as the "field device to be diagnosed." In the example shown in Figure 1, the diagnostic device 5 is configured to communicate with the management device 4 via the network N. The diagnostic device 5 may be a server device (cloud device) located at a distance from the field devices 1 and the management device 4, or it may be an on-premise device located near them. The diagnostic device 5 includes a storage unit 51, a diagnostic unit 52, and an output unit 53.

[0044] The storage unit 51 stores data used by the diagnostic device 5. Examples of data stored in the storage unit 51 include the diagnostic database 511 and the diagnostic program 512.

[0045] The diagnostic database 511 contains data from field devices 1 in which problems have occurred in the past, and whose causes and countermeasures have been identified. Such field devices 1 are also referred to as "reference field devices." The diagnostic database 511 will be explained with reference to Figure 2.

[0046] Figure 2 shows an example of a diagnostic database. The diagnostic database 511 manages the basic data 124 of a reference field device, parameters 125, trouble causes, trouble countermeasures, and operation history 126 in association with each other. In this example, field device 1-1 and field device 1-2 are "reference field devices" and will be referred to as reference field device 1-1 and reference field device 1-2 hereafter.

[0047] A data ID is an identifier that uniquely identifies a piece of data. Figure 1 shows 14 examples of data with data IDs 1 through 14.

[0048] Basic data 124 is used as device management data to uniquely identify field device 1. For example, the device ID included in basic data 124, or a combination of device type and device tag name, can become device management data. Figure 1 schematically shows the device management data for reference field device 1-1 as device management data A000001. The device management data for reference field device 1-2 is schematically shown as device management data A000002.

[0049] Parameter 125, more specifically, here represents the device status. In this example, the device status of reference field device 1-1 is normal for data IDs 1-5 and abnormal for data ID 6. The device status of reference field device 1-2 is normal for data IDs 7-13 and abnormal for data ID 14.

[0050] Trouble factors are the causes of problems occurring in reference field devices 1-1 and 1-2; in other words, they are the causes that led to their abnormal state. Multiple trouble factors may exist for a single abnormal state, and these are described separately as trouble factor 1, trouble factor 2, etc.

[0051] In this example, data ID=6 indicates that Trouble Cause 1 is hydrogen permeation. Hydrogen permeation is the phenomenon of hydrogen ions penetrating the sealing liquid generated in the pressure-receiving part of the pressure transmitter (e.g., the metal diaphragm). This phenomenon is caused by hydrogen contained in the fluid and leads to measurement errors.

[0052] In data ID=14, the cause of trouble 1 is identified as an operational error. This operational error occurred when the operator was operating field device 1. Examples of operational errors include incorrect adjustment procedures for reference field device 1-2, or applying too much pressure.

[0053] Troubleshooting measures are those applied to reference field devices 1-1 and 1-2; in other words, they are measures to restore them to a normal state. Multiple troubleshooting measures may be applied to a single abnormal state, and these are described separately as troubleshooting measure 1, troubleshooting measure 2, etc.

[0054] In this example, data ID=6 indicates that troubleshooting 1=equipment replacement. As the name suggests, equipment replacement means that the reference field equipment 1-1 has been replaced.

[0055] In data ID=14, troubleshooting measures 1 = equipment replacement and troubleshooting measures 2 = operation training. Operation training means that training (education) on operation was provided to the worker who made the operational error in order to prevent the recurrence of the same operational error.

[0056] The operation history 126, more specifically, here refers to operating time and operation volume. The operating time of reference field device 1-1 increases in the order of data ID = 1 to 6. The operating time of reference field device 1-2 increases in the order of data ID = 7 to 14. The operation volume is, for example, the zero adjustment amount mentioned earlier, and its value is shown schematically. In this example, the operation volume of reference field device 1-1 gradually increases as the operating time increases. The operation volume of reference field device 1-2 does not change even with increased operating time, but increases sharply due to an operational error.

[0057] For example, a diagnostic database 511 like the one described above is generated in advance and stored in the storage unit 51. The specific procedure for generation is not particularly limited, and may involve work by, for example, a field device operator, engineer, etc.

[0058] Returning to Figure 1, the diagnostic program 512 stored in the memory unit 51 is a program (software, application program) that enables the computer to function as a diagnostic device 5.

[0059] The diagnostic unit 52 diagnoses the target field device based on the diagnostic database 511 and the data of the target field device. The data of the target field device will be explained with reference to Figure 3.

[0060] Figure 3 shows an example of data for a field device under diagnosis. This data associates the data ID of the field device under diagnosis with basic data 124 (more specifically, device management data), parameters 125 (more specifically, device status), and operation history 126 (more specifically, operating time and operation amount). In this example, field device 1-3 is the "field device under diagnosis" and will be referred to as field device under diagnosis 1-3 hereafter. The device status of field device under diagnosis 1-3 is normal for data IDs 101 to 105 and abnormal for data ID 106.

[0061] For example, data from the diagnostic target field devices 1-3 described above is acquired from the management device 4.

[0062] Returning to Figure 1, the diagnostic unit 52 diagnoses the target field equipment 1-3 based on the diagnostic database 511 and the data of the target field equipment 1-3 (operation history 126, etc.). The diagnosis includes identifying the trouble cause and troubleshooting measures for the target field equipment 1-3.

[0063] First, the diagnostic unit 52 searches the diagnostic database 511 for reference field devices (for example, reference field device 1-1 or reference field device 1-2) that have an operation history 126 similar to that of the field device to be diagnosed. Similarity may be interpreted as including identical devices.

[0064] One example of similarity is the similarity in the time-dependent changes of a manipulated variable (e.g., zero adjustment amount). In this case, the diagnostic unit 52 searches the diagnostic database 511 for a reference field device that has a time-dependent change in a manipulated variable similar to the time-dependent change in the manipulated variable of the field device 1-3 being diagnosed.

[0065] For example, the diagnostic unit 52 calculates the change in the manipulated quantity over time from the operating time and manipulated quantity of the field devices 1-3 under diagnosis, and generates manipulated quantity change data showing the calculation result. The manipulated quantity change data can also be described as data obtained by differentiating the manipulated quantity with respect to operating time (discretizing and differentiating). Similarly, the diagnostic unit 52 generates manipulated quantity change data from the operating time and manipulated quantity of each reference field device in the diagnostic database 511. Then, the diagnostic unit 52 searches the diagnostic database 511 for reference field devices that have manipulated quantity change data similar to the manipulated quantity conversion data of the field devices 1-3 under diagnosis. Various known methods may be used for similarity determination.

[0066] In the examples shown in Figures 2 and 3 described earlier, the operation history 126 of the field device 1-3 under diagnosis and the operation history 126 of the reference field device 1-1 are similar to each other. The diagnostic unit 52 searches the diagnostic database 511 and finds the reference field device 1-2. The diagnostic unit 52 then identifies the trouble cause and trouble countermeasure for the reference field device 1-1, namely hydrogen permeation and device replacement, as the trouble cause and trouble countermeasure for the field device 1-3 under diagnosis.

[0067] In one embodiment, the diagnostic unit 52 may diagnose whether there is a tendency for trouble in the field devices 1-3 that have not yet experienced any trouble. In that case, the diagnostic unit 52 may identify the trouble factors and countermeasures for troubles that may occur in the field devices 1-3 in the future. An example will be explained with reference to Figure 4.

[0068] Figure 4 shows an example of data from a field device being diagnosed. It differs from Figure 3, which was explained earlier, in that it does not include data with data ID=106. The device status of field devices 1-3 being diagnosed is normal, and no problems have occurred.

[0069] Even in this case, since the operation history 126 of the field device 1-3 under diagnosis and the operation history 126 of the reference field device 1-1 (Figure 2) are similar to each other, the diagnostic unit 52 searches the diagnostic database 511 and finds the reference field device 1-1. The diagnostic unit 52 then predicts that the trouble cause of the reference field device 1-1, namely the trouble caused by hydrogen permeation, will occur in the field device 1-3 under diagnosis. Furthermore, the diagnostic unit 52 identifies the trouble countermeasure for the reference field device 1-1, namely equipment replacement, as the trouble countermeasure for the field device 1-3 under diagnosis.

[0070] Returning to Figure 1, the diagnostic unit 52 generates data showing the diagnostic results for the field devices 1-3 under diagnosis. The diagnostic results include the operation history 126 (operating time, amount of operation, etc.), trouble factors, and troubleshooting measures for the identified field devices 1-3 under diagnosis. Other data such as basic data 124, parameters 125, and attached data 127 for the field devices 1-3 under diagnosis may also be included in the diagnostic results.

[0071] The output unit 53 outputs the diagnostic results generated by the diagnostic unit 52. For example, the output unit 53 is configured to include a display, a data output port, etc., and displays the diagnostic results or outputs data. By outputting the diagnostic results, relevant parties, such as the user, operator, and engineer of the field device 1, are informed of the results.

[0072] For example, as described above, a diagnosis of the target field devices 1-3 is performed, including the identification of the trouble causes and countermeasures for the target field devices 1-3, and the diagnosis results are output. Since the diagnostic device 5 automatically diagnoses the target field devices 1-3, it is not necessarily required that an engineer with specialized knowledge spend time performing analysis and other tasks. The frequency of analysis can be reduced, and even when analysis is performed, the analysis time can be shortened. As a result, rapid troubleshooting becomes possible. If the diagnostic unit 52 diagnoses whether there is a tendency for trouble in the target field devices 1-3 before a trouble occurs, the diagnosis results are output, which can help prevent trouble from occurring in the first place.

[0073] The timing of the diagnosis by the diagnostic unit 52 is not particularly limited. For example, the diagnostic unit 52 may access the equipment data 431 in the equipment data storage unit 43 of the management device 4 to monitor the equipment status of each field device 1 and select field devices 1 whose equipment status is abnormal (trouble has occurred) as field devices to be diagnosed. Diagnosis is performed as soon as a problem is detected. By also including field devices 1 whose equipment status is normal (no trouble has occurred) as targets for selection, diagnosis to prevent problems can also be performed in a timely manner. Of course, operators, engineers, etc. may also manually select field devices to be diagnosed by operating the diagnostic device 5.

[0074] The diagnostic database 511 may be updated using the diagnostic results. For example, the diagnostic unit 52 may add the diagnosed field devices 1-3, i.e., the field devices 1-3 whose trouble causes and countermeasures have been identified, to the diagnostic database 511 as new reference field devices. The specific data to be added is shown in Figure 2, which was explained earlier. By accumulating data from more reference field devices in the diagnostic database 511, it is possible to improve the accuracy of subsequent diagnoses of other field devices.

[0075] Figure 5 is a flowchart illustrating an example of the processes (diagnostic methods) performed in relation to the diagnosis. Explanations of content that overlaps with previous explanations will be omitted as appropriate.

[0076] In step S1, the diagnostic database 511 is prepared. The diagnostic database 511 is stored in the storage unit 51 of the diagnostic device 5.

[0077] In step S2, the diagnostic unit 52 of the diagnostic device 5 acquires the operation history of the field equipment to be diagnosed. For example, the operation history 126 of the field equipment 1-3 to be diagnosed, which is included in the equipment data 431 stored in the equipment data storage unit 43 of the management device 4, is acquired. Basic data 124 and parameters 125 of the field equipment 1-3 to be diagnosed may also be acquired.

[0078] In step S3, the diagnostic unit 52 of the diagnostic device 5 searches the diagnostic database 511 for reference field devices whose operation history is similar to that of the field device to be diagnosed. For example, the search finds reference field device 1-1, whose operation history 126 is similar to that of the field device to be diagnosed 1-3.

[0079] In step S4, the diagnostic unit 52 of the diagnostic device 5 identifies the trouble cause and troubleshooting measures for the discovered reference field device as the trouble cause and troubleshooting measures for the field device to be diagnosed. For example, the trouble cause and troubleshooting measures for reference field device 1-1, namely hydrogen permeation and device replacement, are identified as the trouble cause and troubleshooting measures for field device 1-3 to be diagnosed.

[0080] In step S5, the output unit 53 of the diagnostic device 5 outputs the diagnostic results. The diagnostic results, including the trouble cause and troubleshooting measures identified in the previous step S4, are displayed.

[0081] In step S6, the diagnostic unit 52 of the diagnostic device 5 updates the diagnostic database 511. For example, the diagnostic target field devices 1-3, whose trouble cause and troubleshooting measures were identified in the previous step S4, are added to the diagnostic database 511 as new reference field devices. After that, the process returns to step S2.

[0082] After the processing in step S6 is completed, the process returns to step S2. By repeatedly executing the processes in steps S2 to S6, the field devices that have actually experienced problems, or field devices that have not yet experienced problems but show a tendency towards problems, are diagnosed automatically in a timely manner, and the diagnostic results are obtained.

[0083] <Variation> The disclosed technology is not limited to the embodiments described above. For example, the manipulated variable is not limited to the zero adjustment variable. Any manipulated variable that correlates with the trouble of the field device 1 may be used. By accumulating data on various manipulated variables in the diagnostic database 511, many types of troubles can be addressed.

[0084] All data relating to field device 1, such as basic data 124, parameters 125, and operation history 126 (and even attached data 127), may be stored in the diagnostic database 511. Past data such as the model of field device 1, measurement target, operating environment, and trouble cases / countermeasures can be used to propose to the user as factors in determining the specifications of new equipment. For example, if there is a possibility of trouble occurring due to hydrogen permeation, a pressure transmitter having a gold-plated pressure-receiving part (diaphragm part) that is less susceptible to hydrogen permeation can be proposed instead of a normal metal film pressure-receiving part (diaphragm part).

[0085] <Example hardware configuration> Figure 6 shows an example of a hardware configuration. The device, including the computer 9 shown as an example, functions as the field device 1, portable operating device 3, management device 4, or diagnostic device 5 described above. The hardware configuration of the computer 9 is exemplified by a communication device 91, a display device 92, a storage device 93, memory 94, and a processor 95, all of which are interconnected by a bus or the like.

[0086] The communication device 91 is a network interface card or the like, which enables communication with other devices. The communication device 91 may correspond to, for example, the communication IF 15 or field device communication unit 41 described above. The display device 92 may correspond to, for example, the output unit 53 described above.

[0087] Various types of data are stored in the storage device 93 and memory 94. Specific examples of the storage device 93 include HDD (Hard Disk Drive), ROM (Read Only Memory), and RAM (Random Access Memory). Memory 94 may be part of the storage device 93. An example of data stored in the storage device 93 is a program 931. Program 931 is a program (software) that causes the computer 9 to function as a field device 1, a portable operating device 3, a management device 4, or a diagnostic device 5. An example of program 931 is the diagnostic program 512 mentioned earlier, which causes the computer 9 to execute processing performed by the diagnostic unit 52.

[0088] The processor 95 performs various processes. For example, the processor 95 reads program 931 from storage device 93 and loads it into memory 94, thereby causing the computer 9 to execute various processes performed in the field device 1, portable operating device 3, management device 4, or diagnostic device 5.

[0089] Program 931 can be distributed together or separately via a network such as the Internet. Furthermore, Program 931 can be recorded together or separately on computer-readable recording media such as hard disks, flexible disks (FDs), CD-ROMs, MOs (Magneto-Optical disks), and DVDs (Digital Versatile Discs), and executed by a computer 9 after being read from the recording media.

[0090] The technologies described above can be identified, for example, as follows. One of the disclosed technologies is a diagnostic device 5. As explained with reference to Figures 1 to 4, the diagnostic device 5 includes a diagnostic database 511 that manages the operation history 126 of reference field devices 1-1, 1-2, etc., trouble factors, and trouble countermeasures in association with each other, and a diagnostic unit 52 that identifies the trouble factors and trouble countermeasures of the field device 1-3 based on the operation history 126 of the field device 1-3 to be diagnosed. With this diagnostic device 5, the diagnostic database 511 can be used to automatically diagnose the field device 1-3 to be diagnosed, including the identification of the trouble factors and trouble countermeasures for the field device 1-3 to be diagnosed. Therefore, rapid trouble countermeasures become possible.

[0091] The diagnostic unit 52 may search the diagnostic database 511 for a reference field device 1-1 that has an operation history 126 similar to the operation history 126 of the field device 1-3 under diagnosis, and may identify the trouble cause and trouble countermeasure (e.g., hydrogen permeation and equipment replacement) of the reference field device 1-1 found through the search as the trouble cause and trouble countermeasure for the field device 1-3 under diagnosis. The operation history 126 includes the operated quantity (e.g., zero adjustment amount), and the similarity may include the similarity of the change in the operated quantity 126 over time. For example, the trouble cause and trouble countermeasure for the field device 1-3 under diagnosis can be identified by utilizing the diagnostic database 511 in conjunction with such a similarity search.

[0092] The diagnostic unit 52 may identify potential trouble factors and countermeasures for problems that may occur in the field devices 1-3 under diagnosis in the future. This makes it possible to prevent problems in the field devices 1-3 under diagnosis.

[0093] The diagnostic unit 52 may add the diagnostic target field devices 1-3, whose trouble causes and countermeasures have been identified, to the diagnostic database 511 as new reference field devices. By accumulating data from more reference field devices in the diagnostic database 511, it is possible to use this data for diagnosing other diagnostic target field devices in the future.

[0094] The diagnostic device 5 may include an output unit 53 that outputs diagnostic results, including the trouble cause and troubleshooting measures for the field devices 1-3 identified by the diagnostic unit 52. By informing relevant parties of the diagnostic results, it is possible to facilitate prompt troubleshooting.

[0095] The diagnostic method described with reference to Figures 1 to 5 is also one of the disclosed technologies. The diagnostic method includes identifying the trouble cause and troubleshooting measures for the field devices 1 to 3 based on the diagnostic database 511 and the operation history 126 of the field devices 1 to 3 (steps S2 to S4). As explained above, this diagnostic method also enables rapid troubleshooting.

[0096] The diagnostic program 512, as described with reference to Figures 1 to 6, is also one of the disclosed technologies. The diagnostic program 512 causes the computer 9 to perform a process (steps S2 to S4) to identify the trouble cause and trouble countermeasures for the field devices 1 to 3 based on the diagnostic database 511 and the operation history 126 of the field devices 1 to 3 to be diagnosed. As described above, such a diagnostic program 512 also enables rapid trouble countermeasures. A computer-readable recording medium on which the diagnostic program 512 is recorded is also one of the disclosed technologies.

[0097] Some examples of the combinations of technical features that will be disclosed are listed below. (1) A diagnostic database manages the operation history, trouble causes, and troubleshooting measures of a reference field device in an associated manner, and a diagnostic unit identifies the trouble causes and troubleshooting measures of the field device to be diagnosed based on the operation history of the field device to be diagnosed. Equipped with, Diagnostic equipment. (2) The diagnostic unit searches the diagnostic database for reference field devices having operation histories similar to those of the field device under diagnosis, and identifies the trouble causes and troubleshooting measures of the reference field devices found through the search as the trouble causes and troubleshooting measures of the field device under diagnosis. (1) The diagnostic device described above. (3) The aforementioned operation history includes the operation amount, The aforementioned similarity includes the similarity of the change in the manipulated quantity over time. (2) The diagnostic device described above. (4) The aforementioned manipulated variable includes a zero adjustment amount. (3) The diagnostic device described above. (5) The diagnostic unit identifies potential trouble factors and countermeasures for problems that may occur in the field device being diagnosed in the future. A diagnostic device as described in any of (1) to (4). (6) The diagnostic unit adds the field device under diagnosis, whose trouble cause and trouble countermeasures have been identified, to the diagnostic database as a new reference field device. A diagnostic device as described in any of (1) to (5). (7) The diagnostic unit includes an output unit that outputs diagnostic results including the trouble cause and troubleshooting measures for the field device being diagnosed, as identified by the diagnostic unit. A diagnostic device as described in any of (1) to (6). (8) Based on a diagnostic database that manages the operation history, trouble causes, and troubleshooting measures of a reference field device in association with the operation history of the field device being diagnosed, the trouble causes and troubleshooting measures of the field device being diagnosed are identified. including, Diagnostic methods. (9) On the computer, A diagnostic database that manages the operation history, trouble causes, and troubleshooting measures of a reference field device in association with the operation history of the field device to be diagnosed, and a process that identifies the trouble causes and troubleshooting measures of the field device to be diagnosed based on the operation history of the field device to be diagnosed. To execute Diagnostic program. [Explanation of Symbols]

[0098] 100 diagnostic systems 1 Field Equipment 1-1 Reference Field Instruments 1-2 Reference Field Instruments 1-3 Field devices to be diagnosed 11 sensors 12 Calculation / operation management section 121 microprocessors 122 Operation detection unit 123 memory 124 Basic Data 125 parameters 126 Operation History 127 Attached data 13 DA Converters 14 Output Circuit 15 Communication IF 16. Operating switches 2 External circuit 21 Transmission lines 22 DC power supply 23 Resistor 3. Portable operating device 4 Management device 41 Field Equipment Communication Section 42 Equipment Data Management Department 43. Equipment Data Storage Unit 431 Equipment Data 44 User Interface Section 441 Display and setting section for connected devices 442 Display setting section for data storage device 45. Work Report Preparation Department 5. Diagnostic equipment 51 Storage section 511 Diagnostic Database 512 Diagnostic Program 52 Diagnostic Department 53 Output section 9 Computer 91 Communication equipment 92 Display device 93 Storage device 931 Program 94 memory 95 Processor N Network

Claims

1. A diagnostic unit identifies the trouble cause and troubleshooting measures of a field device based on the search results of a diagnostic database that manages the operation history, trouble cause, and troubleshooting measures of a reference field device, and the operation history of the field device to be diagnosed. Equipped with, Diagnostic equipment.

2. The diagnostic unit searches the diagnostic database for reference field devices having operation histories similar to those of the field device under diagnosis, and identifies the trouble causes and troubleshooting measures of the reference field devices found through the search as the trouble causes and troubleshooting measures of the field device under diagnosis. The diagnostic device according to claim 1.

3. The aforementioned operation history includes the amount of operation, The aforementioned similarity includes the similarity of the change in the manipulated quantity over time. The diagnostic device according to claim 2.

4. The aforementioned manipulated variable includes a zero adjustment amount. The diagnostic device according to claim 3.

5. The diagnostic unit identifies potential trouble factors and countermeasures for problems that may occur in the field device being diagnosed in the future. A diagnostic device according to any one of claims 1 to 4.

6. The diagnostic unit adds the field device under diagnosis, whose trouble cause and trouble countermeasures have been identified, to the diagnostic database as a new reference field device. A diagnostic device according to any one of claims 1 to 4.

7. The diagnostic unit includes an output unit that outputs diagnostic results including the trouble cause and troubleshooting measures for the field device being diagnosed, as identified by the diagnostic unit. A diagnostic device according to any one of claims 1 to 4.

8. Based on the search results of a diagnostic database that manages the operation history, trouble causes, and troubleshooting measures of a reference field device in association with the operation history of the field device being diagnosed, the trouble causes and troubleshooting measures of the field device being diagnosed are identified. including, Diagnostic methods.

9. On the computer, A process to identify the trouble cause and trouble countermeasures of a field device under diagnosis, based on the search results of a diagnostic database that manages the operation history, trouble cause, and trouble countermeasures of a reference field device in association with the operation history of the field device under diagnosis. To execute Diagnostic program.

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