Anomaly Sensing and Diagnosis Method, Anomaly Sensing and Diagnosis System, Anomaly Sensing and Diagnosis Program and Enterprise Asset Management and Infrastructure Asset Management System

• US 20130282336A1
• Filed: 11/22/2011
• Published: 10/24/2013
• Est. Priority Date: 12/27/2010
• Status: Abandoned Application

• Current Assignee: Hitachi, Ltd.
• Original Assignee: Hitachi, Ltd.
• Inventors: Maeda, Shunji, Shibuya, Hisae, Magara, Hiroyuki
• Application Number:
  US13/976,147
• Publication Number:
  US 20130282336A1
• Time in Patent Office: Days
• US Class Current: 702/184
• CPC Class Codes: G05B 23/02 Electric testing or monitoring
• CPC Class Codes: G05B 23/0229 knowledge based, e.g. expert systems; genetic algorithms

Abstract

In order to provide a facility of a plant or the like with an anomaly detection/diagnosis method and an anomaly detection/diagnosis system which are capable of detecting an anomaly of the facility with a high degree of sensitivity at an early time, pieces of maintenance-history information composed of past examples such as a work history and information on replaced parts are associated in advance with each other by the appearance frequency (context) of a keyword and, on the basis of anomaly detection making use of signals output by a multi-dimensional sensor installed in the facility as an object, the detected anomaly is linked to the pieces of maintenance-history information which are associated with each other. Thus, at a point of time prediction is detected, it is possible to give a relationship with a countermeasure such as a replacement of a part, an adjustment or a restart.

Claims

1. An anomaly detection/diagnosis method for detecting an anomaly of a plant or a facility or prediction of said anomaly and for diagnosing said plant or said facility, said anomaly detection/diagnosis method including the steps of:

detecting an anomaly of said plant or said facility or prediction of said anomaly by taking sensor data acquired from a plurality of sensors installed in said plant or said facility as an object;

classifying said sensor data of said detected anomaly of said plant or said facility or said detected prediction of said anomaly by making use of maintenance-history information of said plant or said facility; and

outputting a work instruction on the basis of a result of said classification.

2. An anomaly detection/diagnosis method according to claim 1 wherein:

said maintenance-history information includes at least some of on-call data, work reports, adjustments/replaced-part codes, image information and audio information;

an appearance frequency of a keyword determined from said maintenance-history information is computed in order to obtain a pattern of said appearance frequency;

said obtained pattern of said appearance frequency is taken as a category;

said sensor data of said anomaly detected at said plant or said facility or said prediction of said anomaly is classified; and

said work instruction is output on the basis of a result of said classification.

3. An anomaly detection/diagnosis method according to claim 1 whereby:

sensor data is acquired from said sensors;

data included in said acquired sensor data as data composed of almost normal data is modeled as learned data;

said modeled learned data is used to compute an anomaly measure of said acquired sensor data as a vector; and

an anomaly of said plant or said facility is detected on the basis of the magnitude of said computed anomaly measure vector or the angle of said vector.

4. An anomaly detection/diagnosis method according to claim 1 whereby:

sensor data is acquired from said sensors;

data included in said acquired sensor data as data composed of almost normal data is modeled as learned data;

said modeled learned data is used to compute an anomaly measure of said acquired sensor data as a vector; and

an anomaly of said plant or said facility is detected on the basis of a locus generated with the lapse of time as the locus of said computed anomaly measure vector.

5. An anomaly detection/diagnosis system for detecting an anomaly of a plant or a facility or prediction of said anomaly and for diagnosing said plant or said facility, said anomaly detection/diagnosis system comprising:

an anomaly detection section for detecting an anomaly of said plant or said facility or prediction of said anomaly by taking sensor data acquired from a plurality of sensors installed in said plant or said facility as an object;

a database section for storing maintenance-history information of said plant or said facility; and

a diagnosis section for classifying said sensor data used by said anomaly detection section to detect said anomaly of said plant or said facility or said prediction of said anomaly by making use of information stored in said database section to serve as said maintenance-history information of said plant or said facility and for outputting a work instruction on the basis of a result of said classification.

6. An anomaly detection/diagnosis system according to claim 5 wherein:

said maintenance-history information stored in said database section includes at least some of on-call data, work reports, adjustments/replaced-part codes, image information and audio information; and

said diagnosis-model generation section;

computes an appearance frequency of a keyword determined from said maintenance-history information in order to obtain a pattern of said appearance frequency;

takes said obtained pattern of said appearance frequency as a category;

classifies said sensor data of said anomaly detected at said plant or said facility or said prediction of said anomaly; and

outputs said work instruction on the basis of a result of said classification.

7. An anomaly detection/diagnosis system according to claim 5 wherein:

said diagnosis-model generation section acquires sensor data from said sensors installed in said plant or said facility and models data included in said acquired sensor data as data composed of almost normal data as learned data; and

said diagnosis section makes use of said modeled learned data in order to compute an anomaly measure of said sensor data acquired from said sensors as a vector and detects an anomaly of said plant or said facility on the basis of the magnitude of said computed anomaly measure vector or the angle of said vector.

8. An anomaly detection/diagnosis system according to claim 5 wherein:

said diagnosis-model generation section acquires sensor data from said sensors installed in said plant or said facility and models data included in said acquired sensor data as data composed of almost normal data as learned data; and

said diagnosis section makes use of said modeled learned data in order to compute an anomaly measure of said acquired sensor data as a vector and detects an anomaly on the basis of a locus generated with the lapse of time as the locus of said computed anomaly measure vector.

9. An anomaly detection/diagnosis program for detecting an anomaly of a plant or a facility or prediction of said anomaly at an early time and for diagnosing said plant or said facility, said anomaly detection/diagnosis program comprising:

a processing step of detecting an anomaly of said plant or said facility or prediction of said anomaly by taking sensor data acquired from a plurality of sensors installed in said plant or said facility as an object; and

a diagnosis processing step of classifying said sensor data of said detected anomaly of said plant or said facility or said detected prediction of said anomaly by making use of maintenance-history information of said plant or said facility and outputting a work instruction on the basis of a result of said classification.

10. An anomaly detection/diagnosis program according to claim 9 wherein, at said diagnosis processing step:

a keyword is acquired from said maintenance-history information of said plant or said facility;

an appearance frequency of said acquired keyword is used in order to take a pattern of said appearance frequency as a category;

said sensor data of an anomaly of said plant or said facility or prediction of said anomaly, either of which is detected at said processing step of detecting said anomaly or said prediction of said anomaly, is classified into said categories; and

said work instruction is output on the basis of a result of said classification.

11. An enterprise/facility-asset management system comprising:

a database used for storing maintenance-history information including work reports and information on replaced parts;

detection means for detecting an anomaly or prediction of said anomaly through adoption of an identifier such as a subspace method by making use of signal information obtained from a plurality of sensors installed in a plant or a facility;

diagnosis means for diagnosing said anomaly or said prediction of said anomaly, either of which is detected by said detection means, on the basis of a frequency pattern of a keyword paying attention to part replacement or adjustment; and

work requesting means for presenting a request for a work by driving said detection means to detect an anomaly or prediction of said anomaly and by diagnosing said plant or said facility as triggered by said detection.

12. An enterprise/facility-asset management system according to claim 11, said enterprise/facility-asset management system further having phenomenon classification means for classifying an anomaly or prediction of said anomaly, either of which is detected by said detection means, into a phenomenon.

13. An enterprise/facility-asset management system according to claim 12 wherein said phenomenon classification means for classifying an anomaly or prediction of said anomaly, either of which is detected by said detection means, is capable of editing said phenomenon obtained from said classification.

14. An enterprise/facility-asset management system according to claim 11 wherein items of said frequency pattern of said keyword can be edited.

15. An enterprise/facility-asset management system according to claim 11 wherein said frequency pattern of said keyword can be displayed and edited as a context of said facility or a maintenance work.

16. An enterprise/facility-asset management system according to claim 11 wherein items of said frequency pattern of said keyword can be grouped or selected with the lapse of time.

17. An enterprise/facility-asset management system according to claim 11 wherein said keyword is a word, a symbol and a code which have been determined in said enterprise/facility-asset management system and a symbol output in processing such as said anomaly detection.

18. An enterprise/facility-asset management system according to claim 11 wherein said frequency pattern of said keyword is recorded as a pattern and, by utilizing said pattern, said maintenance-history information can be reutilized.

19. An anomaly detection/diagnosis method for detecting an anomaly of a plant or a facility or prediction of said anomaly and for diagnosing said plant or said facility, said anomaly detection/diagnosis method carried out by:

detecting an anomaly of said plant or said facility or prediction of said anomaly by taking sensor data acquired from a plurality of sensors installed in said plant or said facility as an object;

classifying said sensor data of said detected anomaly of said plant or said facility or said detected prediction of said anomaly by making use of pre-stored maintenance-history information of said plant or said facility; and

outputting branch points included in a diagnosis fault tree stored in advance to serve as points which should be verified on the basis of a result of said classification.

20. An anomaly detection/diagnosis method according to claim 19 wherein:

said maintenance-history information includes at least some of on-call data, work reports, adjustments/replaced-part codes, image information and audio information;

an appearance frequency of a keyword determined from said maintenance-history information is computed in order to obtain a pattern of said appearance frequency;

said obtained pattern of said appearance frequency is taken as a category;

said sensor data of said anomaly detected at said plant or said facility or said prediction of said anomaly is classified into the category; and

said branch points included in said diagnosis fault tree to serve as points which should be verified are output on the basis of a result of said classification.