JP2006085573A - Facility equipment maintenance management system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a maintenance management system for equipment and equipment for improving the efficiency of maintenance management by preventing misreading of measurement data and omission of inspection.
A facility equipment maintenance management system that measures operation information of plant equipment and records it in a DB via a communication network to perform maintenance management of parts. An IC tag 12 that senses operation information of the equipment 11 and periodically accumulates measured values is installed for each equipment 11, and the equipment that circulates the equipment 11 and accumulates in the IC tag 12 11 ID number and operation information are extracted and transmitted to the DB server 16 to perform maintenance management of the equipment 11.
[Selection] Figure 1

Description

  The present invention relates to a maintenance management system for facility equipment of various plants, and more particularly to a maintenance management system for facility equipment that saves labor in inspection work and improves the efficiency of maintenance management.

  Conventionally, with respect to maintenance management of various plant equipment, there is a method shown in FIG. 4 as a method for grasping the operating state of equipment to be measured. As shown in the figure, an equipment device inspector attaches a sensing terminal called a header 2 of an acceleration sensor or a temperature sensor to the equipment device 1 to be measured, and displays various operation information on a display device such as a data recorder 3 or a meter. I was getting. In the method of recording the acquired information, an inspector patrols a plurality of inspection points, visually reads the meter, and writes it on the check list prepared in advance by handwriting. The checklist after the inspection was collectively stored in the library 4.

  However, the method shown in FIG. 4 has the following problems. First of all, it is not possible to prevent unauthorized entry due to an inspection person forgetting to visit the inspection location. Moreover, it has not been possible to prevent misreading of the meter display data by the inspector, misprinting when the meter reading result is entered in the list, or misreading due to contamination of the checklist. Furthermore, since the checklist that has been entered is managed in a library, it has been complicated to secure a storage space for documents by accumulating the checklist and to organize data. In addition, it takes a lot of labor and time to search for necessary recorded data.

  In order to solve these problems, a system using a barcode or the like has been proposed. FIG. 5 shows a maintenance management method using a barcode and a computer. As shown in the figure, the inspector installs the barcode 5 or the two-dimensional code at the inspection location of the equipment as described above, and recognizes it using the barcode scanner 6 at the time of inspection. As a result, the part number or the like to be inspected can be specified, and the inspection status can be managed by the computer 7 to prevent the inspector from forgetting to visit.

In recent years, data recorders that can be connected to a network have been developed, which makes it possible to automatically register sensing results in a database (DB), which reduces data errors and inspection work. ing. FIG. 6 shows a conventional method using a data recorder connectable to a network. As shown in the figure, instead of the conventional data recorder, a network-connectable data recorder 8 having a communication unit in the equipment 1 is connected to the equipment. The data recorder 8 that can be connected to the network transmits measurement data to the DB server 9 via a communication line such as WAN or wireless LAN. Also, a monitoring system has been proposed in which the checklist is also converted into a DB and managed by a DB server so that information storage management and retrieval can be easily performed (see, for example, Patent Document 1).
Japanese Patent Laid-Open No. 2004-184400

  However, when a bar code is used to read measurement data, the inspector can easily input equipment information such as part numbers of parts through the bar code, but the meter reading (measurement value) Must be entered manually. For this reason, there is a risk of erroneous input of measurement data. In addition, the ID number may not be recognized due to a dirty barcode.

  In addition, when the network-connectable data recorder described in Patent Document 1 is used, since the data recorder to be used is expensive, the sensing points are practically limited, and it is difficult to maintain and manage the entire plant. Met. Furthermore, since the data record that can be connected to the network is a large-scale device, it cannot be applied to equipment or the like that does not have a space for installation, and there is a problem that the location where the data record is installed is limited.

  Further, at the time of parts replacement, the administrator checks the product number of the corresponding part and the manufacturer and places an order. Therefore, it takes time to search for replacement parts, and the parts cannot be quickly replaced due to the occurrence of a failure. During this time, the equipment stops and production is hindered.

  Accordingly, the present invention provides a maintenance management system for equipment that aims to save labor in inspection work and improve the efficiency of maintenance management by paying attention to the problems of the above prior art and preventing misreading of measurement data and omission of inspection. With the goal.

  In order to achieve the above object, the present invention provides a maintenance management system for equipment that measures operation information of plant equipment and records it in a DB via a communication network and manages the maintenance of parts. An IC tag that senses operation information and periodically accumulates measurement values is installed for each facility device, and the ID number and operation information of the facility device stored in the IC tag is extracted and transmitted to a DB server, It is characterized by maintenance management of equipment.

  In this case, the IC tag records a sensor that senses the operation information of the facility device, a timer that periodically starts measurement of the facility device by the sensor, and a measurement value that is periodically measured by the sensor. And a memory to be used.

  In addition, the IC tag may include a control unit that accumulates a value out of a preset threshold value of the operation information of the equipment equipment among the measurement values of the equipment equipment measured by the sensor.

  In the present invention having the above-described configuration, an IC tag having a sensor, a timer, and a memory is directly installed in a facility device to be inspected in the plant, and the operation information of the facility device periodically acquired by the sensor by the timer is stored for each facility device. Stored in memory.

  As a result, there is no omission of inspection by the inspector, it is possible to prevent erroneous reading of the measurement data, and to save labor in inspection work and increase the efficiency of maintenance management. In addition, since the measurement data to be recorded in the memory is recorded when the threshold value is exceeded, the memory can be saved.

  Further, the memory of the IC tag is read by a scanner, the ID number assigned to the IC tag previously registered in the DB is searched in the connected DB server, and the operation information is registered. For this reason, it is not necessary to install a communication device on the IC tag, and it can be made compact, so that it can be installed even in a narrow installation location.

  A preferred embodiment of a maintenance management system for facility equipment according to the present invention will be described in detail with reference to the accompanying drawings. FIG. 1 shows a schematic configuration diagram of a maintenance management system according to the embodiment. FIG. 2 shows a schematic configuration diagram of an IC tag according to the present embodiment. In the present embodiment, the maintenance management of factory equipment will be described as an example. The following examples are only one aspect of the embodiment of the present invention, and the present invention is not limited to these.

  The equipment management and management system 10 is installed for each equipment 11 to measure and record measurement data, a scanner 14 for reading the data of the IC tag 12, a scanner 14 for reading the data of the IC tag 12, and the scanner 14 for measurement. It is largely composed of a DB server 16 for registering and managing data.

  First, the IC tag 12 includes an antenna unit 18 and an IC unit 20 as shown in FIG. In addition, a power source 22 or a capacitor for increasing the communication distance may be provided.

  The IC unit 20 includes a communication circuit unit 24 that performs reception, transmission, detection, demodulation, modulation, and the like, a logic unit 26 that serves as a control unit that performs data reading, writing, calculation, authentication, encryption, and the like. It is composed of a ROM memory 28 in which a uniquely assigned ID number (part number of equipment to be attached) is written, and a RAM memory 30 in which a user can freely write.

  Further, in the present invention, a timer 32 and a sensor 34 are provided. The sensor 34 has functions of an accelerometer, a thermometer, an ultrasonic meter, a strain meter, and the like, and at least one sensor 34 can be formed in the IC unit 20. On the other hand, the timer 32 can count a certain time and can start the measurement of the sensor 34 periodically. Thereby, the measurement data periodically measured by the sensor 34 can be recorded in the RAM memory 30. The RAM memory 30 can record the measurement time together with the measurement value.

  The timer 32 may be started at a fixed interval, or a threshold value may be set in advance for the measured value of the sensor 34 and accumulated in the memory when the threshold value is exceeded. Alternatively, when an abnormality occurs in the measurement value, it can be stored in the memory. Thereby, memory can be saved.

  The antenna unit 18 is configured to be able to communicate with an antenna 42 of a reader / writer 38 to be described later. Thus, since the IC tag 12 has a configuration in which the entire tag is made compact, it can be easily installed even in various equipment devices 11 having a small installation space such as a motor, a processing apparatus, and a press device. Furthermore, the number of IC tags can be reduced by installing a plurality of sensors 34 on the IC tag 12.

  On the other hand, a PC 36 is installed on the side of the scanner 14 and the DB server 16 that reads the accumulated data of the IC tag. A control software 40 for controlling the reader / writer 38 is mounted on the PC 36 by connecting a reader / writer 38 for communicating with the IC tag 12. An antenna 42 that can communicate with the antenna unit 18 is further connected to the reader / writer 38. When the antenna unit 18 of the IC tag 12 and the antenna 42 connected to the reader / writer 38 approach each other, the antenna unit 18 built in the IC tag 12 receives radio waves from the antenna 42 connected to the reader / writer 38. The communication circuit unit 24 of the IC tag 12 activates each function of the IC tag 12 by the current generated by converting the received radio wave into a current and a signal. The logic unit 26 processes the signal to convert the data in the memory into a signal, and transmits the signal from an antenna built in the IC tag 12. The transmitted signal is received by the antenna 42 connected to the reader / writer 38, converted into a signal by the reader / writer 38, and converted into data by the control software 40 mounted on the PC 36.

  In this embodiment, the scanner 14 and the DB server 16 are connected via a wireless communication 44 such as a wireless LAN. The DB server 16 forms a DB 46 for registering operation information of the IC tag 12. In the DB 46, information on equipment is further registered. In the equipment information, information on the part lifespan such as the model number of the equipment, the supplier of the parts, and the expiration date and limit of use is registered. The facility information registered in the DB 46 can be viewed as a list on the display screen on the PC 36 or the scanner 14.

Further, the DB server 16 forms a life determination means for calculating the expiration date of the component. The life determination unit compares the state information of the equipment newly registered from the IC tag 12 with information on the life of the parts registered in the DB 46 in advance.
Based on the inspection result, it is possible to determine the order of parts that need replacement and the service life of the parts such as the limit of use.

  Further, the DB server 16 is formed so as to be able to place and order with a parts maker via a communication line 48. When there is a part that needs to be replaced, the maintenance management system 10 notifies the person in charge of maintenance management of the equipment, and the DB server 16 is connected to the terminals 50 of a plurality of parts manufacturers. Parts can be ordered automatically. Further, the system 10 is configured so that data registered in advance by a parts maker such as a model number, a contact address, a person in charge, etc. can be rewritten via the communication line 48. Therefore, the user of the maintenance management system 10 does not need to perform maintenance such as maintenance management periodically.

  Note that a radio communication method used for transmission / reception of the IC tag 12 may mainly use electromagnetic induction or a microwave method. In addition, the sensor 34 and the timer 32 may be usually a method that uses a very small amount of current accumulated in an internal capacitor, or a method that converts energy such as vibration and heat acquired by the sensor 34 into a current.

The operation of the facility equipment maintenance management system 10 having the above configuration will be described below. FIG. 3 is a diagram illustrating a processing flow of maintenance management of facility equipment according to the embodiment.
(S102) The IC tag 12 is attached to an inspection location of the equipment 11 such as a motor, a processing device, a press machine, or the like where maintenance of the plant is necessary. The sensor 34 used at this time is necessary to grasp the frequency for the motor and the rotating shaft, the operating time for those that deteriorate over time, such as a processing device, and the number of uses for those that have a limited number of uses such as a press. The sensor 34 is built in the IC tag 12. It should be noted that at least one sensor 34 may be incorporated in the IC tag 12.
(S104) The sensor 34 built in the IC tag 12 senses with a constant period by the timer 32. The fixed period of the timer 32 can be arbitrarily set and can be changed.
(S106) The measurement data and measurement time measured by the sensor 34 at a constant cycle are stored in the RAM memory 30. Although recording can be performed at regular intervals by the timer 32, the RAM memory 30 can be recorded by a method of accumulating values outside the preset threshold value in the RAM memory 30 or by changing the recording interval when the value deviates from the threshold value. The accumulated data can be saved.
(S108) When the inspector patrols, the scanner 14 is held over the IC tag 12 attached to the inspection location, thereby reading and extracting the operation information as the ID number of the equipment and the measurement value accumulated in the IC tag 12. .
(S110) The scanner 14 transmits operation information to the DB server 16 connected by wireless communication 44 such as (wireless) LAN.
(S112) The DB server 16 searches the stored data in the DB 46 for an ID number corresponding to the received operation information.
(S114) The DB server 16 registers the measurement data in the DB 46. The DB 46 includes columns for describing the ID number of the equipment device uniquely assigned to the IC tag 12, the equipment information on which the IC tag 12 is attached, and the inspection result. The information on the equipment equipment 11 includes at least Information on the life of the parts such as the model number of the equipment, the supplier of the parts, and the expiration date and limit of use is registered. Information on the registered equipment 11 can be viewed on the display screen on the scanner 14 and the DB server 16.
(S116) The DB server 16 makes a life judgment by comparing the state information of the equipment registered in the DB server 16 with the information on the life of the parts registered in the DB 46 in advance by the life diagnosis means.
(S118) Based on the result of the life diagnosis, it is determined whether or not replacement is necessary for a component that is approaching the use limit.
(S120) In equipment that requires replacement of parts due to the expiry date of the parts, a warning is sent to the maintenance manager of the equipment, and the part number and quantity of the replacement parts are sent to the parts supplier registered in the DB 46 in advance. Can be automatically transmitted to the parts manufacturer's terminal 50 by e-mail 52.

  As a result, the inspector can easily extract the ID number of the equipment and past measurement data by holding the scanner 14 over the individual IC tags 12 arranged on the equipment in a self-supporting and distributed manner. For this reason, it is possible to prevent erroneous reading of the inspection data displayed on the meter, and erroneous entry or forgetting to enter the check list. In addition, it is possible to prevent the inspector from inspecting and to reduce the number of inspection operations.

Since the IC tag 12 according to the embodiment can periodically accumulate measurement data, the measurer can extract not only the operation data of the equipment at the time of inspection but also the measurement data traced back to the past. Therefore, for example, with a small sensor, it is difficult to measure the thickness of a non-destructive pipe. However, by using an acceleration sensor or the like as means for detecting a piping abnormality in advance, it is possible to detect a piping abnormality by using the measurement as a continuous value.
In this way, the measurement data is highly reliable, and it is possible to provide a maintenance management system for facility equipment that saves inspection work and improves the efficiency of maintenance management.

  The scanner 14 according to the embodiment extracts measurement data by an operator holding it over the IC tag 12, but it may be extracted by using a stationary antenna arranged in advance in the facility for extraction of measurement data. good. This stationary antenna can directly communicate with each IC tag 12 and transmit the extracted data to the DB server 16. Therefore, it is possible to omit the work of sensing with the portable terminal by the worker.

  Further, since the IC tag 12 and the scanner 14 transmit and receive data wirelessly, the IC tag 12 and the scanner 14 can be directly attached to a rotating body such as a rotating shaft, which is difficult to attach in a conventional wired system. Further, since the recording data used in the IC tag 12 is transmitted and received wirelessly, it can be installed even in a sealed space.

  The present invention can also be used for distribution management of factory equipment maintenance management including various types of plant equipment maintenance management or sales operations requiring periodic management.

It is a figure showing the composition outline of the maintenance management system concerning an embodiment. It is a figure which shows the structure outline of the IC tag which concerns on embodiment. It is a figure which shows the processing flow of the maintenance management of the installation equipment which concerns on embodiment. It is a figure which shows the maintenance management of the conventional equipment installation. It is a figure which shows the maintenance management system of the facility equipment using the conventional barcode and computer. It is a figure which shows the maintenance management system of the installation apparatus using the data recorder which can connect the conventional network.

Explanation of symbols

1 ... Equipment, 2 ... Header, 3 ... Data recorder, 4 ... Archive, 5 ... Bar code, 6 ... Bar code scanner, 7 ... Computer, 8 ... Data recorder that can be connected to network 9 ... DB server, 10 ... Maintenance management system, 11 ... Equipment, 12 ... IC tag, 14 ... Scanner, 16 ... DB server, 18... Antenna section 20... IC section 22 Power source 24 Communication circuit 26. Logic section 28 ROM memory 30 RAM memory 32 ......... Timer, 34 ... Sensor, 36 ... PC, 38 ... Reader / writer, 40 ... Control software, 42 ... Antenna, 44 ... Wireless communication, 46 ... DB, 48 ......... Communication line, 50 ......... Terminal, 52 ......... E-mail.

Claims (3)

  A maintenance management system for equipment that measures the operation information of plant equipment, records it in a DB via a communication network, and manages the maintenance of parts. An IC tag for storing the equipment is installed for each facility device, and the ID number and operation information of the facility device stored in the IC tag is extracted and transmitted to a DB server to perform maintenance management of the facility device. Maintenance management system for facility equipment.   The IC tag includes a sensor that senses the operation information of the equipment, a timer that periodically starts measurement of the equipment by the sensor, a memory that records measurement values that the sensor regularly measures, The maintenance management system for facility equipment according to claim 1, comprising:   The IC tag is provided with a control unit that accumulates a value out of a preset threshold value of the operation information of the equipment / equipment among measured values of the equipment / equipment measured by the sensor. The maintenance management system for facility equipment described in 2.

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