JP2000250775A - Trouble analysis supporting device and simulation system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily judge whether a logic circuit is established or not and to confirm a non-recorded relay state in a PLC as well by simultaneously and synchronously confirming conditions before and after the trouble of a facility as input/output information and PLC control information. SOLUTION: A control signal recording part 43 fetches the input/output contact information of a PLC 30 controlling a production facility and records this information in an internal ring buffer and when the signal of trigger detection is received from a trigger detecting part 45, according to designated conditions, a control information log file is outputted to a log file storage part 44. A PLC simulating part 53 simulates the operation of the PLC 30 with the value of an input contact as input and determines the value of an output contact. A differential detecting part 54 compares the value of the output contact of the PLC 30 stored in a control information log file storage part 44-3 with the value of the output contact of the PLC simulating part 53 and detects the difference. An internal PLC display part 55 displays the internal information of the simulated PLC 30 on a display 57 in the format of IEC1131 language.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] 1. Field of the Invention [0002] The present invention relates to a trouble analysis support device and a simulation device for supporting trouble analysis of equipment controlled by a sequence control device using a PLC (programmable logic controller).

[0002]

2. Description of the Related Art Conventionally, as a method for analyzing a trouble of a sequence control equipment using a PLC, 1) an operation state of the equipment is photographed by a video camera, and after trouble occurs, image information photographed by the video camera is viewed. Analyze the trouble of the sequence control equipment 2) Record the input / output contacts of the PLC as a timing chart, analyze the trouble of the sequence control equipment based on this timing chart after the trouble occurs 3) Record the PLC control information during operation, This is input to the simulation equipment of the control equipment and reproduced, and at the same time, the situation of the equipment at that time is captured as images and sound information and reproduced together with the reproduction of the simulation equipment to analyze the trouble of the sequence control equipment. 4) Equipment Image, sound and control information, and based on time stamps in the event of a problem. For example, it is known to analyze the trouble of the sequence control equipment by regenerating the data.

[0005] Further, as a method of automatically determining equipment operation parameters, 5) a method of automatically determining equipment operation parameters in real time from past processing contents of a manufacturing equipment and an internal state before the start of processing 6) and a recipe information Is known as a method of optimization by simulation.

[0004]

However, in the method of 1) using image information captured by a video camera, complicated processing such as continuous imaging of the video camera to a trouble occurrence point is required. In addition, this method has a problem that only information on external equipment can be obtained.

In the method using the timing chart of 2), a) since the timing chart is displayed, it is difficult to associate with the logic circuit of the ladder sequence, and the information is very difficult to read. B) Connection outside the PLC C) The state of the internal contact used for control is not known because only the signals are recorded.
There are problems such as the need to check on a desk while reading one language (ladder, SFC, etc.).

In the method 3), the control equipment to be logged does not necessarily have an appropriate trigger signal for starting logging.
There are problems such as the necessity of preparing an apparatus for separately collecting and processing data just to obtain a recording trigger signal, or the need to develop a processing program for that.

For example, the PLC control device needs to add a ladder program for detecting that the equipment has stopped and to output the information to the recording device, and to provide an output contact. Furthermore, programs and contacts are often designed with marginal capacity, and there is another problem that there is no room for addition.

Further, in the method 4), 1) loss of synchronization occurs due to a shift in clock information of each recording device 2) It is unclear where the image and the control data are truly synchronized 3) Slow There is a problem that no correspondence between the control data and the image can be taken at the time of step or step execution.

In the method 5), it is necessary to accumulate data of past processing contents and internal states before the processing is started, and there is a problem that the data may be enormous depending on the system.

[0010] In the method 6), there is a problem that not only the optimization of the recipe but also the measures including the parts and the delivery unit are required to improve the operation rate of the manufacturing system.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a trouble analysis support apparatus which can easily and surely analyze a trouble of a sequence control equipment.

Another object of the present invention is to provide a trouble analysis support apparatus which can generate an appropriate recording trigger signal by itself without imposing a burden on a control apparatus for controlling facilities to be recorded. .

Another object of the present invention is to provide a trouble analysis support apparatus capable of reducing the number of stoppages of the equipment by eliminating the cause of the malfunction during the operation of the equipment and improving the productivity.

It is another object of the present invention to provide a trouble analysis support apparatus which can synchronize control information with image information and sound information with recording and can perform synchronous reproduction.

[0015]

According to one aspect of the present invention, there is provided a trouble analysis support apparatus for supporting trouble analysis of equipment controlled by a sequence control apparatus. Control information recording means for recording input / output information of the apparatus, simulating means for simulating a sequence control device for controlling the equipment based on the information recorded by the control information recording means, and outputting an internal state of the simulating means And output means.

According to such a configuration, the situation before and after the trouble of the equipment can be simultaneously and synchronously confirmed as the input / output information and the PLC control information.
Since it can be confirmed as the IEC1131 language, that is, a ladder, it can be easily determined whether the logic circuit is established or not. In addition, the state of the relay inside the PLC, which has not been recorded, can also be confirmed. As a result, trouble analysis of the equipment becomes very easy.

According to a second aspect of the present invention, there is provided a trouble analysis support device for supporting trouble analysis of equipment controlled by a sequence control device, wherein a control information recording device records input / output information of the sequence control device for controlling the equipment. Means, simulation means for simulating a sequence control device for controlling the equipment based on the information recorded by the control information recording means, output means for outputting the internal state of the simulation means, and simulation results of the simulation means And a difference detecting means for detecting a difference in the actual recording result.

According to such a configuration, the recording conditions can be arbitrarily set without imposing a load on the equipment control device side.
Also, an arbitrary recording condition can be set by combining a plurality of factors.

According to a third aspect of the present invention, there is provided a trouble analysis support device for supporting trouble analysis of equipment controlled by a sequence control device, wherein the control information recording means for recording a history of control information of the equipment; Simulating means for simulating a sequence control device for controlling the equipment based on the information recorded by the control information recording means, and discriminating means for comparing a simulation result of the simulating means with a normal operation state to discriminate between normal and abnormal. And a database for associating various abnormal factors with a procedure to be eliminated by correction, and control signal output means for outputting a control signal in accordance with the abnormal factor eliminating means of the database.

According to the above configuration, it is possible to reduce retained data and prevent inconvenience in the entire manufacturing system, thereby improving operation efficiency.

According to a fourth aspect of the present invention, there is provided a trouble analysis support device for supporting trouble analysis of equipment controlled by a sequence control device, comprising: state recording means for recording the state of the equipment as an image or an operation sound; Record the input and output information of the sequence control device that controls the equipment, for each integral multiple of the scan time of the sequence control device,
Control information recording means for outputting a synchronization signal to the state recording means, and simulation means for simulating a sequence control device for controlling the equipment based on the information recorded by the control information recording means. Features.

According to such a configuration, it is possible to eliminate the synchronization deviation between the control information and the image information, and it is possible to analyze equipment trouble based on accurate information. In addition, even in slow / step playback, it is possible to clearly know the location where data is synchronized.

According to a fifth aspect of the present invention, there is provided a simulation device connected to a logging device for recording the state of equipment controlled by a sequence control device in image and sound, wherein the recorded image and sound data are recorded. Data reproducing means for reproducing data, a simulation means for simulating the sequence control device, and a difference detecting means for detecting a difference between a reproduction result reproduced by the data reproducing means and a simulation result of the simulation means. It is characterized by.

According to such a configuration, the difference between the simulation result and the actual recording result can be detected, and the trouble analysis of the equipment becomes easy.

[0025]

According to the present invention, the trouble analysis of equipment and the optimization of a control program are supported by the recording result of the equipment logger and the equipment simulation to which the result is input. In addition, by incorporating a recording trigger signal generation mechanism, it is configured to be able to support a wide range of equipment trouble analysis support.

FIG. 1 is a block diagram showing the overall configuration of the first embodiment of the trouble analysis support apparatus according to the present invention.

In FIG. 1, the trouble analysis support apparatus 100 according to the first embodiment is roughly divided into a logging section 40
And a simulation / playback unit 50.

The logging section 40 receives image information of the manufacturing facility based on the acoustic signal of the manufacturing facility collected by the microphone 10, the image signal of the manufacturing facility captured by the camera 20, and the control signal of the manufacturing facility output from the PLC 30. A log file of an audio signal and control information is created, and an audio recording unit 41, an image recording unit 42, a control signal recording unit 43,
It comprises a log file storage unit 44 and a trigger detection unit 45.

Here, the sound recording section 41 takes in the sound signal of the manufacturing equipment collected by the microphone 10 and
This is digitized by PCM or the like and recorded in an internal ring buffer (not shown). When receiving a trigger detection signal from a trigger detection unit 45, which will be described in detail later, the sound recording unit 41 outputs a sound information log file to the log file storage unit 44 according to designated conditions. Here, since the sound recording unit 41 has the ring buffer as described above, recording management of past sound signals is possible.

The image recording section 42 takes in an image signal of the manufacturing equipment taken by the camera (CCD camera) 20, digitizes the signal by JPEG or the like, and records it in an internal ring buffer (not shown). This image recording unit 42
Upon receiving a trigger detection signal from the trigger detection unit 45 described in detail later, the image information log file is output to the log file storage unit 44 according to the designated conditions. Here, since the image recording unit 42 has the ring buffer as described above, recording management of past image signals is possible.

The control signal recording section 43 takes in input / output contact information (IO information) of the PLC 30 controlling the manufacturing equipment, and records the information in an internal ring buffer (not shown). Upon receiving a trigger detection signal from a trigger detection unit 45 described later in detail, the control signal recording unit 43 outputs a control information log file to the log file storage unit 44 according to the specified conditions. Here, the control signal recording unit 43
Has a ring buffer as described above,
Records of past control signals can be managed.

The log file storage unit 44 has an acoustic information log file storage unit 44-1, an image information log file storage unit 44-2, and a control information log file storage unit 44-3.

Here, the acoustic information log file storage unit 44
The acoustic information log file stored at -1 is a file which is taken in from the microphone 10 and stores digitized acoustic information under specified recording conditions.

The image information log file storage unit 44-
2 is a file in which digitized image information captured from the camera 20 is stored under specified recording conditions.

The control information log file storage unit 44-
3 is a file in which digitized control information (input / output contact information) captured from the PLC 30 is stored under designated recording conditions.

The trigger detecting section 45 detects a recording start trigger of logging. Here, PL is used as a trigger input.
When the IO or DM of C30 is designated, the ring buffer of the control signal recording unit 43 is monitored, and when the change of the designated IO or DM is detected, the sound recording unit 41 and the image recording unit 42 are triggered. Notify detection.

The simulation / playback unit 50 includes a sound playback device 51, an image playback unit 52, a PLC simulation unit 53, a difference detection unit 54, a PLC internal display unit 55, a speaker 56, and a display 57.

Here, the sound reproducing device 51 outputs the sound data of the sound information log file stored in the sound information log file storage section 44-1 to the speaker 56.

The image reproducing section 52 outputs the image data of the image information log file stored in the image information log file storage section 44-2 to the display 57.

The PLC simulating section 53 stores the PL to be recorded.
The same program as C30 is read, the operation of the PLC 30 is simulated using the value of the input contact as an input, and the value of the output contact is determined.

The difference detector 54 stores the P of the control information log file stored in the control information log file storage 44-3.
The value of the output contact of the LC 30 is compared with the value of the output contact as a result of the simulation performed by the PLC simulation unit 53, and the difference is detected.

The PLC internal display unit 55 includes a PLC simulation unit 5.
3 displays the internal information of the PLC 30 simulated on the display 57 in the IEC1131 language format. In this embodiment, the internal information of the PLC 30 simulated by the PLC simulating unit 53 is displayed on the display 57 in a ladder format.

FIG. 2 is a diagram showing an example of a display image displayed by the trouble analysis support apparatus according to the first embodiment shown in FIG.

That is, in this embodiment, the recorded image information (moving image), acoustic information, and control signal information of the simulation result can be confirmed almost synchronously. The equipment trouble is analyzed based on these three pieces of information.

Here, the internal state of the PLC 30 is displayed in the IEC1131 language so that a maintenance person can easily understand. FIG. 2 shows a display example of the ladder language.

Also, by setting the simulation speed to 1 / n, it is possible to check the important part slowly.

FIG. 3 is a diagram showing an example of a display image of a difference detection state displayed by the trouble analysis support apparatus of the first embodiment shown in FIG.

If the result of the simulation by the PLC simulating unit 53 is different from the logged control signal information,
The difference information is displayed as shown in FIG. Here, the contact point where the difference is detected is highlighted on the ladder as shown in FIG.
As a result, it is possible to estimate a cause such as noise or contact chattering.

In the configuration shown in FIG. 1, the logging unit 40 and the simulation / playback unit 50 may be the same device, or may be realized as physically separated devices. For example, the logging unit 40 and the simulation / playback unit 50 may be connected via a network.

In this case, when the logging unit 40 and the simulation / playback unit 50 are constituted by the same device, a first aspect is provided.
And, for example, can be configured by a personal computer and software. When the logging unit 40 and the simulation / playback unit 50 are configured separately, the logging unit 40 can be configured with a recording component, the simulation / playback unit 50 can be configured with a personal computer and software, and the simulation / playback unit 50 can be configured with a personal computer and software. In the case of comprising, the configuration of claim 5 is obtained.

The acoustic information log file, the image information log file, and the control information log file may be configured as one log file, or may be configured as a plurality of physically different log files.

When the logging unit 40 and the simulation / playback unit 50 are physically separated from each other, the log file may be located in the logging unit 40. You may comprise so that it may be in the part 50.

Next, the operation of the trouble analysis support apparatus according to the first embodiment will be described in detail with reference to the flowcharts of FIGS.

FIG. 4 is a flowchart showing the operation and the overall operation of the trouble analysis support apparatus according to the first embodiment shown in FIG.

The trouble analysis support apparatus 100 according to the first embodiment is used when trouble occurs in equipment. In the flowchart shown in FIG. 4, the roles of the logging unit 40 and the simulation / playback unit 50 from the occurrence of a trouble to the troubleshooting are shown. When a trouble occurs, the trouble analysis support apparatus 10 of the present invention
Set 0 to the troubled equipment. After that, the trouble is reproduced, and the status of the equipment before and after the trouble is recorded by the logging unit 40.

In FIG. 4, first, a site worker or a maintenance person checks whether there is a facility trouble, and checks whether there is a facility trouble (step 101). If it is determined that there is no equipment trouble (N in step 101)
O) Returning to step 101, if it is determined in step 101 that there is equipment trouble (step 101).
YES), in order to grasp this trouble state, FIG.
The trouble analysis support apparatus 100 shown in (1) is installed in a facility where a trouble has occurred, and data is collected (step 1).
02).

Then, the trigger condition is set and the reproduction of the trouble is waited (step 103). That is, step 1
In step 03, it is checked whether or not the equipment trouble has been reproduced. If the equipment trouble has not been reproduced (NO in step 103), the process returns to step 103.
If it is determined that the equipment trouble has been reproduced (step 10
(YES in 3), the state of the equipment before and after the trouble is recorded / stored in the log file storage unit 44 of the logging unit 40 as image information, sound information, and control information (step 10).
4).

Next, the log file is reproduced by the simulation / reproduction unit 50 (step 105). Before the log file is reproduced, the PLC simulation unit 53 of the simulation / reproduction unit 50 stores the PLC 3 of the target equipment.
The program loaded at 0 is loaded.

When the maintenance staff reproduces the log file, the cause of the trouble is analyzed by confirming the movement of the equipment, the transition of the logical condition of the PLC program, and the sound (step 106).

Then, by analyzing the log file,
If the trouble cause is found (Y in step 107)
ES), the process proceeds to a step 109, where a trouble countermeasure is taken for the target equipment, and this processing ends.

If the cause of the trouble cannot be found in step 107 (NO in step 107), the process proceeds to step 108, where the installation location of the trouble analysis support apparatus 100 and the data to be recorded are reviewed, and the installation is performed again. (Step 108).

FIG. 5 is a flowchart showing the detailed operation of the logging unit of the trouble analysis support apparatus according to the first embodiment shown in FIG.

The logging section 40 logs the image, sound, and control information of the equipment to be recorded. Here, since the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43 of the logging unit 40 have a ring buffer as described above, past information can be recorded. For example, in the recording conditions of the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43, the recording time is 3 minutes, and the recording time after the trigger is 1
When the minute is designated, data of two minutes before the equipment stops due to a trouble and one minute after the trouble occurs can be stored.

In FIG. 5, first, a trigger condition and a recording condition are set (step 111). Here, the trigger condition is, for example, a condition such that a trouble occurs when the contact 10101 of the PLC 30 is turned on. The recording conditions are a recording time T and a post-trigger recording time tr.

Next, the sound recording unit 41 and the image recording unit 4
2 and secures and creates a ring buffer area in the control signal recording unit 43 in which each data can be stored for the recording time T (step 112).

The sound recording unit 41, the image recording unit 42, and the control signal recording unit 43 read data in accordance with each recording rate (step 113), and write the read data to each ring buffer (step 11).
4).

Next, it is checked whether or not the trigger detecting section 45 has detected a trigger (step 115). If the trigger detection unit 45 has not detected a trigger (step 11)
(NO at 5), returning to step 113 to continue recording in the ring buffer.

In step 115, the trigger detector 4
5 is determined to have detected the trigger (step 1).
(YES in 15), it is confirmed whether or not the recording for the recording time after the trigger is detected after the trigger detection, that is, whether or not the set recording time after the trigger has elapsed (step 116). Here, if the set recording time after the trigger has not elapsed (NO in step 116), the process proceeds to step 117, where the sound recording unit 4
1 and the data corresponding to each recording rate by the image recording unit 42 and the control signal recording unit 43 (step 117), and continue the processing of writing the read data to the respective ring buffers (step 118), and return to step 116. .

If it is determined in step 116 that the recording time after the set trigger has elapsed (step 1).
At 16, the process proceeds to step 119 to stop reading new data and stop writing data to the ring buffer.

Thereafter, the data of the ring buffers of the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43 are written into the log file storage unit (information file) 44 in a sequential file format (step 120).
This processing ends.

Here, the sequential file is rearranged from the oldest data on the ring buffer to the latest data and written. Here, the log file may be logically divided into three or physically divided into three.

Each data read into the ring buffer is provided with a time stamp. When reading control data for the first time, a time scan time of the PLC 30 is recorded.

FIG. 6 is a flowchart showing the detailed operation of the simulation / playback unit of the trouble analysis support apparatus according to the first embodiment shown in FIG.

When the trouble situation of the target equipment is reproduced,
In the simulation / reproduction unit 40,
By performing the regeneration operation, the maintenance staff analyzes the trouble of the target equipment.

In this embodiment, instead of simply reproducing the logged facility state, ie, the log file of image information, audio information, and control information, the input contact information of the log file of the control signal is used. Based on this, a simulation of the recording target is performed. Thereby, the internal contact information that is not output to the outside can also be synchronously confirmed as image and sound data. Thus, it is possible to easily analyze a trouble that cannot be detected from only the external contacts, such as a problem with the interlock.

In FIG. 6, first, initialization is performed (step 121). In this initialization, the number of simulation cycles (cycle) and the number of image updates (v
view) to 0. In addition, the simulation execution speed is read. Here, n of 1 / n can be specified as the execution speed of the simulation. That is, the simulation can be executed at a speed of 1 / n. At this time, PL
The program in the IFC1131 language (here, ladder) installed in C is read.

Next, the log data is read from the log file of the sound, image, and control information (step 12).
2). Here, from the log file of the control information, the PLC
30 I / O data and scan time are read.

Next, a simulation for one scan is executed by inputting one data of the log file of the control information, and the internal IO and the contact data of the output (0) are output. Further, the cycle is incremented by 1 and displayed on the display 57 (step 123).

Next, IO information resulting from the simulation is displayed on the ladder program (step 124).
Here, on the ladder program, ON contacts in the IO information are highlighted by hatching as shown in FIG. By scrolling on the display 57, the IO information in all programs can be confirmed.

Next, the value of the output contact of the simulation result and the value of the output contact of the control information log file are all compared (step 125). As a result of this comparison, if there is a difference between the output contact value of the simulation result and the output contact value of the control information log file (N in step 125)
O), proceed to step 126; if there is no difference (YES in step 125), proceed to step 128.

At step 126, the contact number having a difference, the contact value of the control information log and the contact value of the simulation result are displayed as shown in FIG. 3, and the contact having the difference is highlighted on the ladder program. .

Then, with the difference displayed, the operator is prompted to input whether to stop or continue the simulation. Here, if the stop of the simulation is input (NO in step 127), the simulation is ended. If the continuation of the simulation is input (YES in step 127), the simulation is continued ignoring the difference. Go to step 128.

At step 128, it is determined whether or not the simulation is performed in a slow mode, that is, whether the simulation speed is other than 1. Here, if the simulation speed = 1 (YE at step 128)
S), the process proceeds to step 129 to issue a sound data reproduction instruction. If the simulation speed is not set to 1 (NO in step 128), the process proceeds to step 130 without reproducing the sound data.

In step 129, the sound reproducing device 51 is instructed to reproduce sound data for one scan time. Here, the sound reproducing device 51 and the PLC simulation unit 53
Work individually.

At step 130, it is checked whether it is the image update timing. By the way, the control signal recording unit 43 and the image recording unit 42 have different sampling times. That is,
The control signal recording unit 43 records at a scan time cycle of the PLC 30, and the image recording unit 42 records every 30 ms. Therefore, in order to minimize the deviation between the image and the control information, in step 130, the condition INT ((cycle * scan time) / 30)>
The time when (view + 1) holds is determined as the image update timing.

If it is determined in step 130 that the image is to be updated (YES in step 130), the process proceeds to step 131. If it is determined that the image is not to be updated (NO in step 130), the process proceeds to step 132.

At step 131, 1 is added to the view, and the image data of the view sheet of the image information log is displayed on the display 57.

In step 132, it is confirmed that the simulation speed is other than 1. Here, if the simulation speed is not 1 (N in step 132)
O) Since the execution is slow, the process proceeds to step 133, and if the simulation speed = 1 (N in step 132)
O), proceed to step 134;

At step 133, since the simulation speed is slow, a timer is set and the process waits.

In step 134, it is determined whether all the control information logs have been used. The input of the simulation requires the input contact information of the control information log. Therefore, when all the control information logs have been used up (YSE in step 134), the simulation ends.

If it is determined in step 134 that all control information logs have not been used up (N in step 134)
O) Then, it is checked whether the mode is the continuous mode (step 1).
35). Here, in the case of the continuous mode (step 1
(YES at 35), and returns to step 123.

If it is determined in step 136 that the mode is not the continuous mode (NO in step 136), the process waits for a user input in the step execution mode. If there is a user input, go to the next step. That is, in step 136,
If it is determined that there is no next input (N in step 136)
O) Returning to step 136, if it is determined that there is a next input (YES in step 136), step 123
Return to

FIG. 7 is a block diagram showing the overall configuration of the second embodiment of the trouble analysis support apparatus according to the present invention.

In the trouble analysis support apparatus 200 according to the second embodiment shown in FIG. 7, the trigger generation section 46 controls the control signal stored in the control signal recording section 43 and the externally input sensor 60 or the like. The trigger generation unit 46 generates a trigger based on the detection output and the sound information stored in the sound recording unit 41 and the image information stored in the image recording unit 42, that is, the microphone 10 for logging,
The camera 20 and the PLC 30 are configured to be shared for generating a trigger.

That is, in the trouble analysis support apparatus 100 according to the first embodiment shown in FIG. 1, the sound recording section 41 is controlled based on the control signal stored in the control signal recording section 43.
And a trigger for the image recording unit 42 is detected, whereas in the trouble analysis support apparatus 200 according to the second embodiment shown in FIG. In addition to the control signal stored in the memory, a trigger is generated based on the detection output of the sensor or the like 60 input from outside, the sound information stored in the sound recording unit 41, the image information stored in the image recording unit 42, and the like. In this respect, the trouble analysis support device 200 according to the second embodiment differs from the trouble analysis support device 100 according to the first embodiment shown in FIG. Another configuration is the trouble analysis support apparatus 100 according to the first embodiment shown in FIG.
Is the same as

Therefore, in the description of FIG. 7, parts performing the same functions as those of the trouble analysis support apparatus 100 according to the first embodiment shown in FIG. 1 have the same reference numerals as those used in FIG. Description will be made using reference numerals.

In FIG. 7, the trouble analysis support apparatus 200 of the second embodiment is roughly divided into a logging section 40 and a simulation, similarly to the trouble analysis support apparatus 100 of the first embodiment shown in FIG. / Reproducing unit 50.

The logging section 40 is based on the sound signal of the manufacturing equipment collected by the microphone 10, the image signal of the manufacturing equipment captured by the camera 20, and the control information of the manufacturing equipment output from the PLC 30, A log file of an audio signal and control information is created, and an audio recording unit 41, an image recording unit 42, a control signal recording unit 43,
It comprises a log file storage unit 44 and a trigger generation unit 46.

Here, the sound recording unit 41 takes in the sound signal of the manufacturing equipment collected by the microphone 10 and
This is digitized by PCM or the like and recorded in an internal ring buffer (not shown). Upon receiving the trigger signal from the trigger generation unit 46, the sound recording unit 41 outputs a sound information log file to the log file storage unit 44 according to the specified conditions. Here, the sound recording unit 41
Since the ring buffer is provided as described above, recording management of past acoustic signals is possible.

The image recording section 42 takes in an image signal of the manufacturing equipment taken by the camera (CCD camera) 20, digitizes the signal by JPEG or the like, and records it in an internal ring buffer (not shown). This image recording unit 42
When receiving the trigger signal from the trigger generation unit 46, the image information log file is output to the log file storage unit 44 according to the specified condition. Here, the image recording unit 4
2 has a ring buffer as described above, and thus can record and manage past image signals.

The control signal recording unit 43 takes in input / output contact information (IO information) of the PLC 30 controlling the manufacturing equipment and records this in an internal ring buffer (not shown). When receiving the trigger signal from the trigger generation unit 46, the control signal recording unit 43 outputs a control information log file to the log file storage unit 44 according to the specified conditions. Here, since the control signal recording unit 43 has the ring buffer as described above, it is possible to record and manage past control signals.

The log file storage unit 44 has an acoustic information log file storage unit 44-1, an image information log file storage unit 44-2, and a control information log file storage unit 44-3.

Here, the sound information log file storage unit 44
The acoustic information log file stored at -1 is a file which is taken in from the microphone 10 and stores digitized acoustic information under specified recording conditions.

The image information log file storage unit 44-
2 is a file in which digitized image information captured from the camera 20 is stored under specified recording conditions.

The control information log file storage unit 44-
3 is a file in which digitized control information (input / output contact information) captured from the PLC 30 is stored under designated recording conditions.

The trigger generation section 46 generates a recording start trigger for logging. Here, in addition to the control signal stored in the control signal recording unit 43, the trigger generation unit 46 detects the externally input detection output of the sensor 60, the acoustic information stored in the acoustic recording unit 41, and the image recording unit 42. A trigger signal is generated by using the image information stored in the. Therefore,
The trigger generator 46 has various built-in condition setting, program processing, and various information processing functions for generating a recording trigger, as described in detail later, and can respond to various requests.

The simulation / playback unit 50 includes a sound playback device 51, an image playback unit 52, a PLC simulation unit 53, a difference detection unit 54, a PLC internal display unit 55, a speaker 56, and a display 57.

Here, the sound reproducing device 51 outputs the sound data of the sound information log file stored in the sound information log file storage unit 44-1 to the speaker 56.

The image reproducing section 52 outputs the image data of the image information log file stored in the image information log file storage section 44-2 to the display 57.

[0110] The PLC simulating section 53 stores the PL to be recorded.
The same program as C30 is read, the operation of the PLC 30 is simulated using the value of the input contact as an input, and the value of the output contact is determined.

The difference detector 54 stores the P of the control information log file stored in the control information log file storage 44-3.
The value of the output contact of the LC 30 is compared with the value of the output contact as a result of the simulation performed by the PLC simulation unit 53, and the difference is detected.

The PLC internal display unit 55 includes a PLC simulation unit 5
3 displays the internal information of the PLC 30 simulated on the display 57 in the IEC1131 language format. In this embodiment, the internal information of the PLC 30 simulated by the PLC simulating unit 53 is displayed on the display 57 in a ladder format.

In the configuration shown in FIG. 7, the logging unit 40 and the simulation / playback unit 50 may be the same device, or may be realized as physically separated devices. For example, the logging unit 40 and the simulation / playback unit 50 may be connected via a network.

The acoustic information log file, the image information log file, and the control information log file may be configured as one log file, or may be configured as a plurality of physically different log files.

When the logging unit 40 and the simulation / playback unit 50 are physically separated from each other, the log file may be located in the logging unit 40. You may comprise so that it may be in the part 50.

FIG. 8 is a block diagram showing the entire configuration of a third embodiment of the trouble analysis support apparatus according to the present invention.

The trouble analysis support apparatus 200 according to the second embodiment shown in FIG. 7 includes a control signal stored in a control signal recording section 43, a detection output of a sensor 60 and the like input from outside, and a sound recording. The trigger generation unit 46 generates a trigger based on the acoustic information stored in the unit 41 and the image information stored in the image recording unit 42, that is, the microphone 10 for logging, the camera 20, the PLC
8 is used for generating a trigger, while FIG.
A trouble analysis support device 300 according to the third embodiment shown in FIG.
Is a separate microphone 60- for trigger generation.
1, a camera 60-2 and a PLC 60-3 are provided, and the microphone 60-1, the camera 60-2 and the PLC 60-3 are provided.
The trigger generation unit 47 generates a trigger signal by using the signal from. Other configurations are the same as those of the trouble analysis support device 200 according to the second embodiment shown in FIG.

That is, in the trouble analysis support device 300 according to the third embodiment, the trigger generation unit 47
In addition to the control signal stored in the control signal recording unit 43, the detection output of the sensor 60 or the like input from outside, the sound recording unit 41
A trigger signal is generated using the acoustic information stored in the image recording unit and the image information stored in the image recording unit. Therefore, as will be described in detail later, the trigger generation unit 46 has various condition settings, program processing, and various information processing functions for generating a recording trigger, and can respond to various requests.

The recording start trigger for logging is generated as follows: 1) All information to be recorded, that is, a part of image information, acoustic information, various PLC information, and various external information is input to the recording unit, and these are triggered. Configuration that also serves as generation information 2) All information to be recorded, that is, a part of image information, audio information, various PLC information, and various external information is input to the recording unit, and a part of them also serves as trigger generation information. Configuration 3) All information to be recorded, that is, image information, acoustic information, PLC various information, and part of various external information are input to the recording unit, and independently of them, information for recording trigger generation, that is, image information, A configuration in which all or part of acoustic information, various PLC information, and various external information is separately input. 4) All information to be recorded, that is, one of image information, acoustic information, various PLC information, and various external information. It is possible to adopt a configuration in which a unit is input to the recording unit and only information of a different type is input for trigger generation.

FIG. 9 is a block diagram showing a detailed configuration of the trigger generation unit according to the present invention.

In FIG. 9, this trigger generation section 470
Is various input information to be recorded in the trouble analysis support device,
Based on an external signal input only for generating a recording instruction or a combination thereof, these are processed by a program to generate an optimal trigger signal required by the user.

That is, in FIG. 9, the trigger generation section 470 includes an execution processing section 471 and a program storage section 47.
2. Data storage unit 473, communication interface (communication I
/ F) 474.

Here, the execution processing section 471 reads out the program in the program storage section 472, executes processing of input data such as image information, audio information, PLC control information, and other external signals, and embeds it in the program. It is determined whether or not the generated trigger generation condition / logic is satisfied / not satisfied, and a trigger signal is generated.

The program storage section 472 stores a program for generating a trigger signal based on arbitrary conditions using input data. Here, the program storage unit 47
The mounting storage medium 2 corresponds to a storage such as a semiconductor memory or a magnetic medium. Personal computer and PL
A trigger generation program created externally, such as a C development environment, is stored via the communication I / F 474, and this program is executed by the execution processing unit 471 during operation.

The data storage unit 473 stores a data pattern to be detected as reference information and temporarily stores various types of input information. Here, the data storage unit 4
The mounting storage medium 73 corresponds to a storage such as a semiconductor memory or a magnetic medium, and may be the same physical medium as the program storage unit 472 or an independent physical medium. Externally created data such as a personal computer or a PLC development environment can be stored via the communication I / F 474. During operation, a processing program such as pattern matching accesses the data storage unit 473 and reads out the corresponding data.

The communication I / F 474 is used to download a trigger generation program to the trouble analysis support apparatus and to write settings. However, when the download is unnecessary, the communication I / F 474 may not be provided.

FIG. 10 is a flowchart showing a recording trigger generation process in the trigger generation section shown in FIG.

In FIG. 10, first, the trigger generation section 47
Data such as image information, sound information, PLC control information, and other external signals are input to 0 (step 201).

Next, it is determined whether a predetermined trigger condition is satisfied based on the input data (step 202).
If the trigger condition is not satisfied (step 20)
(NO in 2), return to step 201, and wait until the trigger condition is satisfied.

If it is determined in step 202 that the trigger condition is satisfied (YES in step 202).
S), a trigger signal is output to an input control unit such as the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43 to notify the trigger input (step 203).

The trigger generation section 470 has the following various program processing functions for determining whether or not the trigger condition of step 202 shown in FIG. 10 is satisfied.

1) Sequence Processing Function The determination of the satisfaction / non-satisfaction of the trigger condition by the sequence processing function is performed by detecting a condition by a ladder program based on the control information of the PLC. The details will be described in the first embodiment. As you did.

2) Image Processing Function The determination of the satisfaction / non-satisfaction of the trigger condition by the image processing function is performed by pattern matching processing such as mark, shape,
Condition detection is performed by size pattern matching processing, and is performed by comparison with a past image, detection of a specified color, detection of a specified line / frame overflow, crossing detection, and the like.

3) Acoustic processing function The determination as to whether the trigger condition is satisfied or not by the acoustic processing function is performed by pattern matching, comparison with past acoustic information, detection of a gain threshold, detection of a specific frequency, phase, and the like.

4) Signal Processing Function The signal processing function determines whether the trigger condition is satisfied / unsatisfied by pattern matching processing, comparison with past signal patterns, gain threshold detection, detection of specific frequency, phase, etc.
The detection is performed by edge level change detection, pulse width detection, AND / OR condition detection by inputting a plurality of signals, analog value detection, and the like.

The configuration of the trigger generation unit 470 is as follows: 1) Built-in sequence processing function + image processing function 2) Built-in sequence processing function + sound processing function 3) Built-in sequence processing function + signal processing function 4) Built-in sequence processing function + image processing function + sound processing function 5) Built-in sequence processing function + image processing function + signal processing function 6) Built-in sequence processing function + sound processing function + signal processing function 7) Sequence processing function + image Built-in processing function + sound processing function + signal processing function 8) Built-in image processing function + sound processing function 9) Built-in image processing function + sound processing function + signal processing function 10) Built-in sound processing function + signal processing function etc. Can be adopted.

The trigger generating section 470 has the following temporal processing separately from the above-mentioned program processing function.

1) Delay or time-up processing 2) Specific time detection processing

These processes can be used alone or in combination with the above-mentioned program processing function.

FIG. 11 is a view for explaining an example of the determination of the satisfaction / non-satisfaction of the trigger condition by the image processing function in the trigger generation unit.

Whether the trigger condition is satisfied or not satisfied by the image processing function in the trigger generation unit is determined by performing image processing based on the image data.

In the example shown in FIG. 11, an input image from a camera is binarized, and an inspection window is set in a part of the binarized image. Then, a recording start trigger is generated based on the state of the image in the inspection window, and the trigger is notified to the input control units such as the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43.

In this case, the following settings can be made for determining whether the trigger condition is satisfied / not satisfied.

1) The recording object goes out of the inspection window. 2) The recording object has entered the inspection window. 3) The recording target in the inspection window has stopped.

FIG. 11 shows a case where the object to be inspected is a picking robot. When the picking robot goes out of the inspection window, it is determined that the operation is abnormal and a recording start trigger is transmitted to the input control unit. .

In FIG. 11, a physical movement is used as a trigger like a picking robot. However, for example, an object that can detect a change on an image, such as an image of blinking / extinguishing of a lamp, is used as a trigger. Can be used as

FIG. 12 is a diagram for explaining an example of the determination of the satisfaction / non-satisfaction of the trigger condition by the sound processing function in the trigger generation unit.

In this case, the trigger generation unit generates a trigger by performing predetermined sound processing based on the sound data.

In FIG. 12, an acoustic signal to be inspected is picked up by a microphone input, the frequency component of the acoustic signal is obtained by Fourier expansion, and when the gain exceeds a specific frequency, the equipment operation is judged to be abnormal. , This is the sound recording unit 41,
The input control units such as the image recording unit 42 and the control signal recording unit 43 are notified.

In this case, the following settings can be made for determining whether the trigger condition is satisfied / not satisfied.

1) The gain of a certain frequency exceeds or falls below a set threshold value. 2) A specific frequency appears or disappears.

The above processing can be regarded as an example of digital signal processing.

FIG. 13 is a flowchart for explaining an example of the determination of the satisfaction / non-satisfaction of the trigger condition by the pattern matching process in the trigger generation unit.

That is, in the processing shown in FIG.
The pattern information to be detected is stored in advance as reference information, and the stored reference information is compared with information input at the present time to detect a match or mismatch, and a recording trigger is generated based on the match.

In FIG. 13, a trigger is generated when the reference information matches the information input at the present time.

That is, in FIG. 13, first, an initialization process is performed (step 211), and then input data is read (step 212).

Then, it is checked whether the reference information matches the information inputted at the present time (step 213). If the reference information does not match the information input at the current time (NO in step 213), the process returns to step 212 and waits until the reference information matches the information input at the current time.

If it is determined in step 213 that the reference information matches the information input at the present time (YES in step 213), the sound recording unit 41 and the image recording unit 4
2. A trigger input is notified to an input control unit such as the control signal recording unit 43 (step 214).

FIG. 14 is a flow chart for explaining an example of the judgment of the satisfaction / non-satisfaction of the trigger condition by the comparison processing with the past information in the trigger generation unit.

In FIG. 14, the previous input information is temporarily stored in the data storage unit, and the information is compared with the information input at the present time to detect a match or a mismatch. Generate In FIG. 13, a trigger is generated when the previously stored information matches the information input at the present time.

That is, in FIG. 14, first, an initialization process is performed (step 231), and then the input data is temporarily stored in the data storage unit (step 232).

Then, the next data is read (step 233), and it is checked whether the data in the data storage unit matches the current data (step 234). If the data in the data storage unit does not match the current data (NO in step 234), the current data is overwritten and stored in the data storage unit (step 235), and the process returns to step 233.

If it is determined in step 234 that the data in the data storage unit matches the current data (YES in step 234), the sound recording unit 41 and the image recording unit 4
2. A trigger input is notified to an input control unit such as the control signal recording unit 43 (step 236).

FIG. 15 is a flowchart for explaining an example of a delay or time-up process in the trigger generation unit.

In the delay or time-up processing shown in FIG. 15, first, the timer is initialized (step 24).
1). In this timer initialization, a predetermined timer value is set.

Next, it is checked whether or not a timer decrement start event has occurred (step 242). Here, the occurrence of the timer decrement start event is, for example, ON of a predetermined timer contact. Here, the timer contact is a specific input contact assigned for this function.
This allocation method can be realized by, for example, setting a contact on the sequence processing program in advance to this function.

If it is determined in step 204 that the timer decrement start event has not occurred (step 2).
(NO at 42), the process returns to step 204, and waits for the occurrence of a timer decrement start event.

If it is determined in step 242 that a timer decrement start event has occurred (YES in step 242), a timer value decrement process is performed (step 243), and it is then checked whether the timer value = 0. (Step 244). If it is determined that the timer value is not equal to 0 (NO in step 244), the process proceeds to step 2
Return to 43.

When it is determined in step 244 that the timer value is 0 (YES in step 244),
Sound recording unit 41, image recording unit 42, control signal recording unit 43
Is notified of the trigger input (step 24)
5).

FIG. 16 is a flow chart for explaining an example of the specific time detecting process in the trigger generating section.

In the specific time detecting process shown in FIG. 16, the time to be recorded is set in advance, the timekeeping information is constantly monitored from the calendar clock in the trouble analysis support apparatus, and when the set time is reached, the trigger input is acoustically recorded. Part 41,
The input control units such as the image recording unit 42 and the control signal recording unit 43 are notified.

That is, in FIG. 16, first, it is checked whether it is the set time (step 251). If it is not the set time (NO in step 251), the process returns to step 251 and waits for the set time.

If it is determined in step 251 that it is the set time (YES in step 251), the sound recording unit 4
1. A trigger input is notified to input control units such as the image recording unit 42 and the control signal recording unit 43 (step 252).

FIG. 17 is a block diagram showing the overall configuration of the fourth embodiment of the trouble analysis support apparatus according to the present invention.

In the trouble analysis support apparatus 400 according to the fourth embodiment shown in FIG. 17, the PLC simulation unit 53 simulates the PLC 30 based on the information on the operation of the target equipment, and the difference detection unit At 54, the difference is detected, and the content is notified to the correction instruction processing unit 59. The correction instruction processing section 59 is configured to obtain correction contents from the correction processing information storage section 58 based on the notified difference contents, and to notify the PLC 30 and other correction processing devices 70 of the correction contents. Other configurations are the same as those of the trouble analysis support device 200 according to the second embodiment shown in FIG.
Here, the trouble analysis support device 2 of the second embodiment
Parts that perform the same functions as 00 are given the same reference numerals as those used in FIG. 7, and detailed descriptions thereof are omitted.

FIG. 18 is a flowchart for explaining the operation of the trouble analysis support apparatus according to the fourth embodiment shown in FIG.

In FIG. 18, first, control information of the PLC 30 is collected by the control signal recording unit 43 (step 30).
1) The collected control information is stored in the log file storage unit 44.
Is stored in the control information log file storage unit 44-3 (step 302).

Next, the operation of the PLC 30 is simulated by the PLC simulation unit 53 based on the control information stored in the control information log file storage unit 44-3 of the log file storage unit 44 (step 303).

Next, the difference detecting section 54 outputs the value of the output contact point of the PLC 30 of the control information log file stored in the control information log file storage section 44-3 and the PLC simulation section 53.
Is compared with the value of the output contact as a result of the simulation to check whether correction is necessary (step 304).

If it is determined that correction is not necessary (NO in step 304), the correction information is updated (step 305), and the process returns to step 301.

If it is determined in step 304 that correction is necessary (YES in step 304), it is checked whether correction processing has been selected (step 30).
6) If there is no correction processing, return to step 301,
If there is a correction process, the correction process is performed by the correction process instructing section 59.
(Step 307).

FIG. 19 is a view for explaining the operation of selecting the correction processing shown in FIG.

In FIG. 19, the difference detecting unit 54 stores a normal parameter in each state, that is, state 1, state 2,..., State n in advance.
, 542-n. When a simulation result parameter obtained as a result of the simulation of the operation of the PLC 30 is input from the PLC simulation unit 53, the simulation result parameter is Comparison section 5
41, normal parameter storage units 542-1, 542
, 542-n, that is, the normal parameters in the states 1, 2, 3,.

From the result of this comparison, it is determined whether or not the simulation result parameter obtained as a result of the simulation of the operation of the PLC 30 by the PLC simulation unit 53 is within the allowable range or outside the range in which the processing can be continued.

Here, the PLC3 by the PLC simulation unit 53
If it is determined that the simulation result parameter obtained as a result of the simulation of the operation of 0 is normal and out of the allowable range in which the processing can be continued, the mismatch parameter in this case is notified to the correction processing instruction unit 59 and the correction processing instruction unit 59 Searches the correction data in the correction processing storage unit 58 based on the mismatch parameter, and stores the searched correction data in the PLC 30
And the other correction processing device 70.

The PLC simulating unit 53 controls the PLC 30
When it is determined that the simulation result parameter obtained as a result of the simulation of the operation is normal and within the allowable range in which the processing can be continued, the simulation result parameter is notified to the correction processing storage unit 58.

The correction processing storage unit 58 is a database that stores PLC I / O compulsory control for performing normal control processing, instructions for changing memory contents, operation information of a dedicated correction control device, and the like. The operation information of the correction instruction result is fed back and updated.

According to the fourth embodiment, it is possible to reduce the amount of stored data, prevent inconvenience in the whole manufacturing system, and improve the operation efficiency.

For example, in a machining line, if a simulation result, that is, a time out of the next stroke monitoring timer occurs due to a distance delay in the previous stroke, that is, a stroke end timing, and an inconvenience is predicted in the next stroke, the following correction processing To prevent the occurrence of inconvenient products.

1) Increasing the speed of the conveyor belt to speed up the start of the next step. 2) Extend the timer value of the next stroke monitoring timer. 3) Remove the parts using a robot arm or the like.

It should be noted that, based on the processing results of the above 1), 2), 3), etc., the state of solving the inconvenience in the subsequent processing is reflected in the database of the correction processing storage unit 58.

FIG. 20 is a block diagram showing the overall configuration of the fifth embodiment of the trouble analysis support apparatus according to the present invention.

The trouble analysis support device 500 of the fifth embodiment shown in FIG. 20 is basically the same as the trouble analysis support device 100 of the first embodiment shown in FIG. In the trouble analysis support apparatus 500 according to the fifth embodiment, a synchronization signal is transmitted to the image recording unit 42 and the sound recording unit 41 at an integral multiple of a specific signal, such as a scan time of the PLC 30, or a fixed period. By transmitting a synchronization signal to the control signal recording unit 43, the image recording unit 42, and the sound recording unit 41 every time, the recording of the control information, the image information, and the sound information is synchronized, and the synchronized reproduction is realized at the time of reproduction. It is configured.

According to such a configuration, 1) it is possible to eliminate the synchronization deviation between the control information and the image information, and it is possible to analyze the equipment trouble based on the accurate information. 2) Even if slow or frame-by-frame playback is performed, The timing at which the image and the control information data are synchronized can be understood. 3) Since the data at the time of recording is synchronized, effects such as easy synchronized reproduction can be expected.

That is, in FIG. 20, the trouble analysis support apparatus 500 according to the fifth embodiment is roughly composed of a logging section 40 and a simulation / playback section 50.

[0196] The logging section 40 is based on the audio signal of the manufacturing equipment collected by the microphone 10, the image signal of the manufacturing equipment taken by the camera 20, and the control signal of the manufacturing equipment output from the PLC 30, and A log file of an audio signal and control information is created, and an audio recording unit 41, an image recording unit 42, a control signal recording unit 43,
It comprises a log file storage unit 44 and a trigger detection unit 45.

Here, the sound recording unit 41 takes in the sound signal of the manufacturing equipment collected by the microphone 10 and
This is digitized by PCM or the like and recorded in an internal ring buffer (not shown). When receiving the trigger detection signal from the trigger detection unit 45, the sound recording unit 41 outputs a sound information log file to the log file storage unit 44 according to the specified conditions. Here, the sound recording unit 4
1 has a ring buffer as described above, and thus can record and manage past acoustic signals.

Further, the sound recording section 41 receives the synchronization signal from the control signal recording section 43 and records the synchronization signal on the recording data.

The image recording section 42 takes in an image signal of the manufacturing facility taken by the camera 20, digitizes the image signal by JPEG or the like, and records it in an internal ring buffer (not shown). The image recording unit 42 includes a trigger detection unit 45
Receives the trigger detection signal from the server, stores the image information log file in the log file storage unit 44 according to the designated conditions.
Output to Here, since the image recording unit 42 has the ring buffer as described above, recording management of past image signals is possible.

[0200] Further, the image recording section 42 receives the synchronization signal from the control signal recording section 43, and outputs this synchronization signal to the camera 20. The image signal from the camera 20 is updated for each synchronization signal from the control signal recording unit 43.

Here, the camera 20 is constituted by a CCD camera, and operates by receiving an external synchronization signal from the image recording unit 42.

The control signal recording unit 43 takes in input / output contact information (IO information) of the PLC 30 that controls the manufacturing equipment, and records this in an internal ring buffer (not shown). Upon receiving the trigger detection signal from the trigger detection unit 45, the control signal recording unit 43 outputs a control information log file to the log file storage unit 44 according to the specified conditions. Here, since the control signal recording unit 43 has the ring buffer as described above, it is possible to record and manage past control signals.

The control signal recording section 43 stores the recording target P
LC30 scan time, ie, data update period t
s information and scan time INT (33 ms)
A synchronization signal is sent to the sound recording unit 41 and the image recording unit 42 every (ec / ts + 1) times.

The log file storage unit 44 has an acoustic information log file storage unit 44-1, an image information log file storage unit 44-2, and a control information log file storage unit 44-3.

Here, the acoustic information log file storage unit 44
The acoustic information log file stored at -1 is a file which is taken in from the microphone 10 and stores digitized acoustic information under specified recording conditions.

Further, the image information log file storage section 44-
2 is a file in which digitized image information captured from the camera 20 is stored under specified recording conditions.

The control information log file storage unit 44-
3 is a file in which digitized control information (input / output contact information) captured from the PLC 30 is stored under designated recording conditions.

The trigger detecting section 45 detects a recording start trigger of logging. Here, PL is used as a trigger input.
When the IO or DM of C30 is designated, the ring buffer of the control signal recording unit 43 is monitored, and when the change of the designated IO or DM is detected, the sound recording unit 41 and the image recording unit 42 are triggered. Notify detection.

[0209] The simulation / playback unit 50 includes a sound playback device 51, an image playback unit 52, a PLC simulation unit 53, a difference detection unit 54, a PLC internal display unit 55, a speaker 56, and a display 57.

Here, the sound reproducing device 51 outputs the sound data of the sound information log file stored in the sound information log file storage unit 44-1 to the speaker 56.

[0211] The image reproducing section 52 outputs the image data of the image information log file stored in the image information log file storage section 44-2 to the display 57.

[0212] The PLC simulating section 53 stores the PL to be recorded.
The same program as C30 is read, the operation of the PLC 30 is simulated using the value of the input contact as an input, and the value of the output contact is determined.

[0213] The difference detection unit 54 stores the P of the control information log file stored in the control information log file storage unit 44-3.
The value of the output contact of the LC 30 is compared with the value of the output contact as a result of the simulation performed by the PLC simulation unit 53, and the difference is detected.

The PLC internal display unit 55 includes a PLC simulation unit 5
3 displays the internal information of the PLC 30 simulated on the display 57 in the IEC1131 language format. In this embodiment, the internal information of the PLC 30 simulated by the PLC simulating unit 53 is displayed on the display 57 in a ladder format.

In the configuration shown in FIG. 20, the logging unit 40 and the simulation / playback unit 50 may be the same device, or may be realized as physically separated devices. For example, the logging unit 40 and the simulation / playback unit 50 may be connected via a network.

Further, the acoustic information log file, the image information log file, and the control information log file may be configured as one log file, or may be configured as a plurality of physically different log files.

When the logging unit 40 and the simulation / playback unit 50 are physically separated from each other, the log file may be located in the logging unit 40. You may comprise so that it may be in the part 50.

FIG. 21 is a diagram showing the state of the update cycle of the NTSC image signal and the control signal of the PLC 30 output from the camera shown in FIG.

In FIG. 21, the control signal of the PLC 30 is updated every rising of the signal, that is, every several m to several tens msec as shown in FIG. On the other hand, the NTSC image signal output from the camera 20 is 1/3
It is updated every 0 msec.

For this reason, the control signal of the PLC 30 has changed several times or more while the image signal of the NTSC system output from the camera 20 is updated by one frame. However, the update cycle of the image signal is not always an integral multiple of the update cycle of the control signal. For this reason, it is impossible to know at which timing the image signal displayed during reproduction is synchronized with the control signal. This becomes remarkable when performing slow reproduction.

In the conventional synchronous reproduction based on the time stamp, for example, the image data recorded at t1 and the t
The control data recorded in c1 is reproduced so as to be synchronized.
This is because the image data closest to the time tc1 is the time tc1.
Because it is 1.

Strictly speaking, however, the image data recorded at time t1 is fixed on the camera 20 only at time t0.
It is. Therefore, the control information at time tc1 and the time t1
And a difference of about 1/30 msec. During this time, the control data is updated several times.

As described above, the synchronous reproduction based on the time stamp of the recording time does not always perform the accurate synchronous reproduction. Therefore, for example, when analyzing a trouble by associating control information with the state of a display device such as a chip mounter, a soft drink manufacturing device or a high-speed moving device or an LED, it is a problem that accurate synchronous reproduction is not performed. become.

FIG. 22 shows the fifth embodiment of the present invention shown in FIG.
It is a figure which shows the data synchronization image in the trouble analysis support apparatus of Embodiment of this invention.

That is, the basic concept of data synchronization in the trouble analysis support apparatus 500 according to the fifth embodiment of the present invention is to clarify the timing at which image information and control signals are reliably synchronized. . This can be realized by: 1) updating the image signal at an integral multiple of the cycle at which the control signal is updated. 2) matching the timing at which the control signal is updated with the timing at which the image information is determined.

Therefore, in the trouble analysis support apparatus 500 according to the fifth embodiment, the image update cycle is set to an integral multiple of ts seconds in order to create a timing at which the control signal and the image information are completely synchronized.

Generally, in an NTSC camera, 1 /
Image data cannot be taken out in less than 30 msec. Therefore, INS (33 msec / ts + 1)
= Update the image signal every time the control signal is updated M times. The synchronization timing can be inserted by inputting a magic number to the data digitized for each ts * M.

With such a configuration, synchronization between the control information data recorded at time t0 and the image information data recorded at time t1 can be realized. On the other hand, during reproduction, the control information data recorded at time t0 and the image information data recorded at time t1 are reproduced in synchronization. Thereby, at least a state where the control signal information and the image information signal at the time t0 are synchronized can be realized.

FIG. 23 is a flowchart showing the detailed operation of the logging unit of the trouble analysis support apparatus according to the fifth embodiment shown in FIG.

The logging section 40 logs the image, sound, and control information of the equipment to be recorded. Here, since the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43 of the logging unit 40 have a ring buffer as described above, past information can be recorded. For example, in the recording conditions of the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43, the recording time is 3 minutes, and the recording time after the trigger is 1
When the minute is designated, data of two minutes before the equipment stops due to a trouble and one minute after the trouble occurs can be stored.

In FIG. 23, first, a trigger condition and a recording condition are set (step 401). Here, the trigger condition is, for example, that the contact 10101 of the PLC 30 is ON.
Then it is a condition that it is a trouble. Also,
The recording conditions are a recording time T and a post-trigger recording time tr.

Next, the sound recording unit 41 and the image recording unit 4
2 and a ring buffer area capable of storing the data for the recording time T is secured in the control signal recording unit 43 (step 402).

Here, the control signal recording section 43 reads the scan time ts of the connected PLC 30. Further, the image information update cycle (M = INT (33 msec / t)
s + 1).

The sound recording unit 41, the image recording unit 42, and the control signal recording unit 43 read data in accordance with each recording rate (step 403), and write the read data to each ring buffer (step 40).
4).

The sound recording unit 41 and the image recording unit 4
2 and details of the operation of the control signal recording unit 43 will be described later with reference to FIG.
This will be described with reference to the flowchart shown in FIG.

Next, it is checked whether or not the trigger detecting section 45 has detected a trigger (step 405). If the trigger detection unit 45 has not detected a trigger (step 40)
(NO at 5), returning to step 403 to continue recording in the ring buffer.

At step 405, the trigger detecting section 4
5 is determined to have detected the trigger (step 4
05, YES), it is confirmed whether or not the recording for the recording time after the trigger is detected after the trigger detection, that is, whether or not the set recording time after the trigger has elapsed (step 406). Here, if the set recording time after the trigger has not elapsed (NO in step 406), the process proceeds to step 407, where the sound recording unit 4
1 and the data corresponding to each recording rate by the image recording unit 42 and the control signal recording unit 43 (step 407), the read data is written to the respective ring buffers (step 408), and the process returns to step 406. .

If it is determined in step 406 that the recording time after the set trigger has elapsed (step 4).
(YES at 06), the process proceeds to step 409 to stop reading new data and stop writing data to the ring buffer.

Thereafter, the data of the ring buffers of the sound recording unit 41, the image recording unit 42, and the control signal recording unit 43 are written into the log file storage unit (information file) 44 in a sequential file format (step 410).
This processing ends.

Here, the sequential file is rearranged from the oldest data on the ring buffer to the latest data and written. Here, the log file may be logically divided into three or physically divided into three.

The sound recording unit 41, the image recording unit 42,
The control signal recording units 43 operate independently.

FIG. 24 is a flowchart showing the operation of the control signal recording unit, the image recording unit, and the sound recording in the flowchart shown in FIG.

FIG. 24A shows the operation of the control signal recording unit 43 in the trouble analysis support device 500 according to the fifth embodiment of the present invention.

In FIG. 24A, the control signal recording section 4
3 first sets a timer until the next control information collection time comes (step 411). Here, the timer value is
This is the scan time ts of the PLC 30.

Next, the process waits until a timeout occurs (step 412).
ES), whether it is the first operation or the timing of transmitting a synchronization signal, that is, cycle = 0 OR
Check whether MOD (cycle) = M (Step 4)
13). Here, if it is a synchronization signal transmission timing, a synchronization signal is transmitted to the image recording unit 42 and the sound recording unit 41 (step 414), and if it is the first operation, a control signal is read from the PLC 30 and a cycle is performed. 1 in
The addition is performed (step 415).

FIG. 24B shows the operation of the image recording unit 42 in the trouble analysis support device 500 according to the fifth embodiment of the present invention.

In FIG. 24B, the image recording section 42
Waits for the input of a synchronization signal from the control signal recording unit 43 (step 421). When a synchronization signal is input (YES in step 421), a synchronization signal is provided to camera 20 so as to send an image signal currently determined by camera 20 (step 422). The image information obtained by the synchronization signal is stored in the ring buffer at the next synchronization signal input.

Next, the image information determined in the previous synchronization signal input is read (step 423). Here, this image data is stored in the image recording section 42 between the time when the synchronization signal is input and the time when the current synchronization signal is input. Is image information stored in the ring buffer.

FIG. 24C shows the operation of the sound recording unit 41 in the trouble analysis support device 500 according to the fifth embodiment of the present invention.

In FIG. 24C, the sound recording section 41
First, the timer is set until the next acoustic signal collection time comes (step 431). And timeout,
That is, wait until the data collection time comes (step 43).
2).

If a timeout occurs in step 432 (YES in step 432), an acoustic signal is read from microphone 10 (step 433).

Next, it is confirmed whether or not there is a synchronization signal from the control signal recording section 43 (step 434). Here, if there is a synchronization signal from the control signal recording unit 43 (step 434)
YES), the acoustic information is converted to a magic number, for example, 8
If it is a bit, it is replaced with 0xFF or the like, and is used as a mark where a synchronization signal has been found (step 435).

FIG. 25 is a flowchart showing the detailed operation of the simulation / playback unit of the trouble analysis support apparatus according to the fifth embodiment shown in FIG.

If the trouble situation of the target equipment is reproduced,
In the simulation / reproduction unit 50, the simulation /
By performing the regeneration operation, the maintenance staff analyzes the trouble of the target equipment.

Here, in this embodiment, instead of simply reproducing the state of the equipment that has logged, that is, the log file of image information, audio information, and control information, the input contact information of the log file of control signals is transmitted. Based on this, a simulation of the recording target is performed. Thereby, the internal contact information that is not output to the outside can also be synchronously confirmed as image and sound data. Thus, it is possible to easily analyze a trouble that cannot be detected from only the external contacts, such as a problem with the interlock.

In FIG. 25, first, initialization is performed (step 441). In this initialization, the number of simulation cycles (cycle) and the number of image updates (view) are set to zero. In addition, the simulation execution speed is read. Here, n of 1 / n can be specified as the execution speed of the simulation. That is, the simulation can be executed at a speed of 1 / n. At this time,
The program of the IFC1131 language (here, ladder) installed in the PLC is read.

Next, logging data is read from the log file of each information of sound, image, and control information (step 4).
42). Here, from the log file of the control information, PL
The I / O data and scan time of C30 are read.

The image update timing M = INT (3
3msec / ts + 1) is calculated.

Next, a simulation for one scan is executed by inputting one data of the log file of the control information, and the internal IO and the contact data of the output (0) are output. Further, the cycle is incremented by 1 and displayed on the display 57 (step 443).

Next, the IO information resulting from the simulation is displayed on the ladder program (step 444).
Here, on the ladder program, ON contacts in the IO information are highlighted by hatching as shown in FIG. By scrolling on the display 57, the IO information in all programs can be confirmed.

Next, the value of the output contact of the simulation result and the value of the output contact of the control information log file are all compared (step 445). As a result of this comparison, if there is a difference between the output contact value of the simulation result and the output contact value of the control information log file (N in step 445)
O), proceed to step 126; if there is no difference (YES in step 445), proceed to step 128.

In step 446, the contact number having a difference, the contact value of the control information log and the contact value of the simulation result are displayed as shown in FIG. 3, and the contact having a difference is highlighted on the ladder program. .

Then, while the difference is displayed, the operator is prompted to input whether to stop or continue the simulation. Here, if the stop of the simulation is input (NO in step 447), the simulation is ended. If the continuation of the simulation is input (YES in step 447), the simulation is continued ignoring the difference. Go to step 448.

At step 448, it is determined whether or not the simulation is executed in a slow mode, that is, whether the simulation speed is other than 1. Here, if the simulation speed = 1 (YE at step 448)
S), proceeding to step 449 to issue a sound data reproduction instruction, but if the simulation speed has not become 1 (NO in step 448), the flow proceeds to step 130 without reproducing sound data.

In step 449, the sound reproducing device 51 is instructed to reproduce sound data for one scan time. Here, the sound reproducing device 51 and the PLC simulation unit 53
Work individually.

In step 450, the update timing for synchronizing the image signal and the image-attached signal is set when the condition MOD (cycle) = M is satisfied.

If it is determined in step 450 that the image is to be updated (YES in step 450), the process proceeds to step 451. If it is determined that the image is not to be updated (NO in step 450), the process proceeds to step 452.

In step 451, 1 is added to the view, and the image data of the view sheet in the image information log is displayed on the display 57.

In step 452, it is confirmed that the simulation speed is other than 1. Here, if the simulation speed is not 1 (N in step 452)
O) Since the execution is slow, the process proceeds to step 453, and if the simulation speed is 1 (N in step 452)
O), proceed to step 454;

At step 453, since the simulation speed is slow, a timer is set to wait.

In step 454, it is determined whether all the control information logs have been used. The input of the simulation requires the input contact information of the control information log. Therefore, when all the control information logs have been used up (YSE in step 454), the simulation ends.

If it is determined in step 454 that all control information logs have not been used up (N in step 454)
O) Then, it is checked whether the mode is the continuous mode (step 4).
55). Here, in the case of the continuous mode (step 4
55 is YES), and returns to step 443.

If it is determined in step 136 that the mode is not the continuous mode (NO in step 456), the flow waits for a user input in the step execution mode. If there is a user input, go to the next step. That is, in step 136,
If it is determined that there is no next input (N in step 456)
O) Returning to step 136, if it is determined that there is a next input (YES in step 456), step 443
Return to

[0274]

As described above, according to the first aspect of the present invention, 1) since the control information of the PLC can be confirmed in the IEC1131 language, that is, a ladder, etc., the establishment / non-establishment of the logic circuit is easy. 2) It is possible to check the relay status inside the PLC that has not been recorded. 3) As a result, it is possible to easily analyze the trouble of the equipment.

According to the second aspect of the present invention, 1) the recording condition can be set arbitrarily without imposing a load on the equipment control device 2) the arbitrary recording condition can be set by combining a plurality of factors. Has the effect of

Further, according to the invention of claim 3, 1) Eliminating the cause of the trouble during the operation of the line reduces the stop of the line, improves the operation efficiency, and can increase the productivity. 2) Automatically detects the cause of the abnormality. Eliminating this can reduce the maintenance staff's work that had to be done at the time of the outage. 3) It is possible to reduce training for maintenance staff and facilitate the development of production lines.

Further, according to the invention of claim 4, 1) it is possible to eliminate the synchronization deviation between the control information and the image information, and it is possible to analyze equipment trouble based on accurate information. 2) Even in slow / step reproduction, This has the advantage that the location where the data is synchronized can be clearly known.

Further, according to the fifth aspect of the present invention, it is possible to detect a difference between a simulation result and an actual recording result, and it is possible to easily analyze equipment trouble.

[Brief description of the drawings]

FIG. 1 is a first diagram of a trouble analysis support device according to the present invention.
FIG. 2 is a block diagram showing an overall configuration of the embodiment.

FIG. 2 is a diagram illustrating an example of a display image displayed by the trouble analysis support apparatus according to the first embodiment illustrated in FIG. 1;

FIG. 3 is a diagram showing an example of a display image of a difference detection state displayed by the trouble analysis support device according to the first embodiment shown in FIG. 1;

FIG. 4 is a flowchart showing operation and overall operation of the trouble analysis support apparatus according to the first embodiment shown in FIG. 1;

FIG. 5 is a flowchart showing a detailed operation of a logging unit of the trouble analysis support device according to the first embodiment shown in FIG.

FIG. 6 is a flowchart showing a detailed operation of a simulation / playback unit of the trouble analysis support device according to the first embodiment shown in FIG.

FIG. 7 shows a second example of the trouble analysis support device according to the present invention.
FIG. 2 is a block diagram showing an overall configuration of the embodiment.

FIG. 8 shows a third embodiment of the trouble analysis support apparatus according to the present invention.
FIG. 2 is a block diagram showing an overall configuration of the embodiment.

FIG. 9 is a block diagram showing a detailed configuration of a trigger generation unit according to the present invention.

FIG. 10 is a flowchart illustrating a recording trigger generation process in a trigger generation unit illustrated in FIG. 9;

FIG. 11 is a diagram illustrating an example of determining whether a trigger condition is satisfied / not satisfied by an image processing function in a trigger generation unit.

FIG. 12 is a diagram illustrating an example of determination of satisfaction / non-satisfaction of a trigger condition by a sound processing function in a trigger generation unit.

FIG. 13 is a flowchart illustrating an example of determining whether a trigger condition is satisfied / not satisfied by a pattern matching process in a trigger generation unit.

FIG. 14 is a flowchart illustrating an example of determination of satisfaction / non-satisfaction of a trigger condition by comparison processing with past information in a trigger generation unit.

FIG. 15 is a flowchart illustrating an example of a delay or time-up process in a trigger generation unit.

FIG. 16 is a flowchart illustrating an example of a specific time detection process in a trigger generation unit.

FIG. 17 is a block diagram showing the overall configuration of a fourth embodiment of the trouble analysis support apparatus according to the present invention.

FIG. 18 is a flowchart illustrating the operation of the trouble analysis support apparatus according to the fourth embodiment shown in FIG.

FIG. 19 is a diagram illustrating an operation of selecting a correction process illustrated in FIG. 18;

FIG. 20 is a block diagram showing the overall configuration of a fifth embodiment of the trouble analysis support apparatus according to the present invention.

21 is an NTS output from the camera shown in FIG. 20.
FIG. 4 is a diagram illustrating a state of an update cycle of an image signal of the C system and a control signal of the PLC 30;

FIG. 22 is a diagram showing a data synchronization image in the trouble analysis support apparatus according to the fifth embodiment of the present invention shown in FIG.

FIG. 23 is a flowchart showing a detailed operation of a logging unit of the trouble analysis support apparatus according to the fifth embodiment shown in FIG.

24 is a flowchart showing operations of a control signal recording unit, an image recording unit, and sound recording in the flowchart shown in FIG.

FIG. 25 is a flowchart showing a detailed operation of a simulation / playback unit of the trouble analysis support device according to the fifth embodiment shown in FIG.

[Explanation of symbols]

 Reference Signs List 10 microphone 20 camera 30 PLC 40 logging unit 41 sound recording unit 42 image recording unit 43 control signal recording unit 44 log file storage unit 45 trigger detection unit 46 trigger generation unit 47 trigger generation unit 50 simulation / reproduction unit 51 sound reproduction device 52 image Reproduction unit 53 PLC simulation unit 54 Difference detection unit 55 PLC internal display unit 56 Speaker 57 Display 58 Correction processing information storage unit 59 Correction processing instruction unit 60 Sensors 70 Correction processing device

Continued on the front page (72) Inventor Yukihiro Kawakami F-term (reference) 5B048 AA15 CC02 CC17 DD17 5H223 AA06 CC03 CC08 DD03 EE06 FF04 FF05

Claims (5)

[Claims] 1. A trouble analysis support device for supporting trouble analysis of equipment controlled by a sequence control device, wherein: control information recording means for recording input / output information of the sequence control device for controlling the equipment; A trouble analysis support device comprising: simulation means for simulating a sequence control device for controlling the equipment based on information recorded by the means; and output means for outputting an internal state of the simulation means. 2. A trouble analysis support device for supporting trouble analysis of equipment controlled by a sequence control device, wherein: control information recording means for recording input / output information of the sequence control device for controlling the equipment; Simulation means for simulating a sequence control device for controlling the equipment based on the information recorded by the means, output means for outputting an internal state of the simulation means, and detecting a difference between a simulation result of the simulation means and an actual recording result. A trouble analysis support device, comprising: 3. A trouble analysis support apparatus for supporting trouble analysis of equipment controlled by a sequence control device, wherein: a control information recording means for recording a history of control information of the equipment; and information recorded by the control information recording means. Simulating means for simulating a sequence control device for controlling the equipment based on the simulating means, comparing the simulation result of the simulating means with the state of normal operation, determining means to determine normal or abnormal, and various abnormal factors A trouble analysis support device, comprising: a database that associates a procedure to be eliminated by correction; and a control signal output unit that outputs a control signal in accordance with an abnormality factor eliminating unit of the database. 4. A trouble analysis support apparatus for supporting trouble analysis of equipment controlled by a sequence control device, wherein: a state recording means for recording the state of the equipment by image or operation sound; and a sequence control device for controlling the equipment. Control information recording means for recording a synchronizing signal to the state recording means for each integral multiple of the scan time of the sequence control device, and information based on the information recorded by the control information recording means. And a simulation means for simulating a sequence control device for controlling the equipment. 5. A simulation device connected to a logging device for recording a state of equipment controlled by a sequence control device in an image and a sound, wherein the data reproduction means reproduces the recorded image and sound data; A simulation apparatus comprising: simulation means for simulating the sequence control device; and difference detection means for detecting a difference between a reproduction result reproduced by the data reproduction means and a simulation result of the simulation means.