JP2021060967A - Programmable logic controller - Google Patents

Abstract

To efficiently collect and transfer data to be monitored in a PLC.SOLUTION: A PLC has a first execution engine, holding means and second execution engine. Further, the PLC collects data stored in the holding means for an object to be collected according to a predetermined collection setting, stores the collected time-series data in a first buffer, and transfers the time-series data stored in the first buffer to the second execution engine via a bus. The second execution engine processes the transferred time-series data, generates display data for display on the dashboard, and provides an external computer with the display data.SELECTED DRAWING: Figure 4

Description

The present invention relates to a programmable logic controller.

A programmable logic controller (PLC) is a controller that controls industrial machines such as manufacturing equipment, transfer equipment, and inspection equipment in factory automation (Patent Documents 1 and 2). The PLC controls various expansion units and controlled devices by executing a user program such as a ladder program created by a programmer.

Japanese Patent No. 5661222 JP-A-2018-097662

By the way, in order to monitor the operation of the PLC and the operation of the industrial machine controlled by the PLC, it is desired to collect and utilize the data held by the PLC. The PLC has a basic unit (CPU unit) and an expansion unit connected to the basic unit (CPU unit). The basic unit controls the expansion unit by executing a user program such as a ladder program. The expansion unit controls the industrial machine according to the command from the basic unit and returns the control result to the basic unit. Here, in order to reduce the load on the basic unit, the inventors came up with the idea of connecting the data utilization unit to the basic unit as one of the expansion units. However, since the control cycle of the expansion unit and the control cycle of the basic unit (scan cycle of the user program) are different, various problems occur. For example, if an expansion unit collects device values from the base unit's device memory according to its own control cycle, it will miss data that is refreshed during each base unit scan cycle. That is, only one device value can be collected for each of a plurality of scan cycles. On the other hand, if the base unit collects and transfers device values during the end processing period at the end of the scan cycle, the base unit cannot move to the next scan cycle unless the device value collection and transfer is complete. That is, the scanning cycle is extended, and the work efficiency of the industrial machine is lowered.

Therefore, an object of the present invention is to efficiently collect and transfer data to be monitored in a PLC.

The present invention is, for example,
The first execution engine that repeatedly executes the first user program,
A plurality of holding means that are devices or variables that store data accessed by the first execution engine according to the first user program.
A second execution engine that executes the second user program asynchronously with the scan cycle of the first user program,
A programmable logic controller having a bus connecting the first execution engine and the second execution engine.
A collection means for collecting data stored in the holding means to be collected among the plurality of holding means according to a predetermined collection setting for each scan cycle of the first user program.
A first buffer that stores time-series data collected for each scan cycle by the collection means,
A transfer means for transferring the time-series data stored in the first buffer to the second execution engine via the bus, and
Have,
The second execution engine
A processing means for processing the time-series data transferred by the transfer means according to a predetermined processing setting, and
A generation means for generating display data for displaying the processing result of the data processing on the dashboard, and
Provided is a programmable logic controller having a providing means for providing the display data to an external computer.

According to the present invention, it is possible to efficiently collect and transfer data to be monitored in a PLC.

Diagram showing PLC system Diagram explaining a PC Diagram explaining a PC Diagram illustrating PLC Diagram explaining the basic unit Diagram explaining the data utilization unit Diagram illustrating an expansion unit Diagram illustrating the format of a data record The figure explaining the transfer timing Diagram illustrating the format of a data record Diagram illustrating information compression Diagram showing an example dashboard Flowchart showing collection and transfer methods Flowchart showing collection and transfer methods Flowchart showing collection and transfer methods Diagram explaining the use case of subbuffer Diagram explaining the dashboard display screen for status monitoring Diagram explaining the dashboard display screen for setting Flowchart showing real-time monitoring method Flowchart showing how to reset in the data utilization unit Flowchart showing dynamic change processing of monitoring target Diagram showing the collected data when the monitoring target is dynamically changed

Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. The following embodiments do not limit the invention according to the claims, and not all combinations of features described in the embodiments are essential to the invention. Two or more of the plurality of features described in the embodiments may be arbitrarily combined. In addition, the same or similar configurations are given the same reference number, and duplicate explanations are omitted. A lowercase alphabet may be added to the end of the reference code indicating the same or similar elements. Lowercase alphabets are omitted when explaining things that are common to multiple elements.

<System configuration>
First, a general PLC configuration and its operation will be described so that a person skilled in the art can better understand a programmable logic controller (PLC, which may be simply referred to as a programmable controller).

FIG. 1 is a conceptual diagram showing a configuration example of a programmable logic controller system according to an embodiment of the present invention. As shown in FIG. 1, this system is a PLC (programmable logic controller) 1 for comprehensively controlling a PC2a for editing a user program such as a ladder program and various control devices installed in a factory or the like. And have. PC is an abbreviation for personal computer. The user program may be created using a graphical programming language such as a ladder language or a flowchart-type motion program such as SFC (sequential function chart), or may be created using a high-level programming language such as C language. .. In the following, for convenience of explanation, the user program will be a ladder program. The PLC 1 includes a basic unit 3 having a built-in CPU and one or a plurality of expansion units 4. One or more expansion units 4 can be attached to and detached from the basic unit 3.

The basic unit 3 includes a display unit 5 and an operation unit 6. The display unit 5 can display the operating status of each expansion unit 4 attached to the basic unit 3. The display unit 5 switches the display content according to the operation content of the operation unit 6. The display unit 5 usually displays the current value (device value) of the device in the PLC1, the error information generated in the PLC1, and the like. The device is a name indicating an area on a memory provided for storing a device value (device data), and may be called a device memory. The device value is information indicating the input state from the input device, the output state to the output device, and the state of the internal relay (auxiliary relay), timer, counter, data memory, etc. set on the user program. There are two types of device values: bit type and word type. The bit device stores a 1-bit device value. The word device stores the device value of one word. Not only the device but also the variable may be specified as the collection target of the data utilization program described in detail below. However, both devices and variables are holding means for holding information. Therefore, in the following description, device also refers to a variable. The memory that holds the device may be called a device memory. Further, the memory that holds the collected data may be called a data memory.

The expansion unit 4 is prepared to expand the function of the PLC1. A field device (controlled device) 10 corresponding to the function of the expansion unit 4 may be connected to each expansion unit 4, whereby each field device 10 is connected to the basic unit 3 via the expansion unit 4. Be connected. The field device 10 may be an input device such as a sensor or a camera, or an output device such as an actuator. Further, a plurality of field devices may be connected to one expansion unit 4.

For example, the expansion unit 4b may be a positioning unit that drives a motor (field device 10) to position the work, or may be a counter unit. The counter unit counts signals from an encoder (field device 10) such as a manual pulsar.

The expansion unit 4a collects data to be collected from the basic unit 3 and the expansion unit 4b, and executes a user program (data utilization program) such as a flow to process the collected data to create display target data. , A data collection unit that creates display data (source data) for displaying a dashboard on the display unit 7 or PC 2. The flow (flow program) described below is just an example of a data utilization program. The basic unit 3 is sometimes called a CPU unit. The system including PLC1 and PC2 may be called a programmable logic controller system.

PC2a is a computer mainly operated by a programmer. On the other hand, PC2b is a computer mainly operated by a person in charge at the site. PC2a may be called a program creation support device (setting device). The PC 2 is, for example, a portable notebook-type or tablet-type personal computer or smartphone, and is an external computer including a display unit 7 and an operation unit 8. The external computer is a computer outside the PLC1. A ladder program, which is an example of a user program for controlling PLC1, is created using PC2a. The created ladder program is converted into a mnemonic code in PC2a. The PC 2 is connected to the basic unit 3 of the PLC 1 via a communication cable 9 such as a USB (Universal Serial Bus) cable. For example, PC2a sends a ladder program converted into a mnemonic code to the basic unit 3. The basic unit 3 converts the ladder program into machine code and stores it in the memory provided in the basic unit 3. Although the mnemonic code is transmitted to the basic unit 3 here, the present invention is not limited to this. For example, the PC 2a may convert the mnemonic code into an intermediate code and transmit the intermediate code to the basic unit 3.

Although not shown in FIG. 1, the operation unit 8 of the PC 2 may include a pointing device such as a mouse connected to the PC 2. Further, the PC 2 may be configured to be detachably connected to the basic unit 3 of the PLC 1 via a communication cable 9 other than the USB cable. Further, the PC 2 may be connected to the basic unit 3 of the PLC 1 by wireless communication without going through the communication cable 9.

<Program creation support device>
FIG. 2 is a block diagram for explaining the electrical configuration of the PC 2a. As shown in FIG. 2, the PC 2a includes a CPU 11a, a display unit 7a, an operation unit 8a, a storage device 12a, and a communication unit 13a. The display unit 7a, the operation unit 8a, the storage device 12a, and the communication unit 13a are each electrically connected to the CPU 11a. The storage device 12a includes a RAM, a ROM, an HDD, and an SSD, and may further include a removable memory card. CPU is an abbreviation for central processing unit. ROM is an abbreviation for read-only memory. RAM is an abbreviation for random access memory. HDD is an abbreviation for hard disk drive. SSD is an abbreviation for solid state drive.

The user of the PC 2a causes the CPU 11a to execute the project editing program 14a stored in the storage device 12a, and edits the project data 15 through the operation unit 8a. When the CPU 11a executes the project editing program 14a, the project creation unit 16 and the project transfer unit 17 are realized. The project creation unit 16 creates the project data 15 according to the user input. The project transfer unit 17 transfers the project data 15 to the PLC1. The project data 15 includes one or more user programs (eg, a ladder program) and configuration information of the basic unit 3 and the expansion unit 4. The configuration information includes information indicating the connection positions of a plurality of expansion units 4 with respect to the basic unit 3, functions provided in the basic unit 3 (example: communication function and positioning function), and functions of the expansion unit 4 (example: shooting function). It is information indicating such as. Here, the editing of the project data 15 includes the creation and modification (re-editing) of the project data 15. The user can read the project data 15 stored in the storage device 12a as needed, and change the project data 15 by using the project editing program 14a. The communication unit 13a communicates with the basic unit 3 via the communication cable 9a. The project transfer unit 17 transfers the project data to the basic unit 3 via the communication unit 13a. The communication unit 13a communicates with the expansion unit 4a via the communication cable 9b.

<PC used to display the dashboard>
FIG. 3 is a block diagram for explaining the electrical configuration of the PC 2b. As shown in FIG. 3, the PC 2b includes a CPU 11b, a display unit 7b, an operation unit 8b, a storage device 12b, and a communication unit 13b. The display unit 7b, the operation unit 8b, the storage device 12b, and the communication unit 13b are each electrically connected to the CPU 11b. The storage device 12b includes a RAM, a ROM, an HDD, and an SSD, and may further include a removable memory card.

The CPU 11b realizes the Web browser 18 by executing the Web browser program 14d. The Web browser 18 accesses the setting page of the data utilization application provided by the expansion unit 4a or the dashboard page via the communication unit 13b.

<PLC>
FIG. 4 is a block diagram for explaining the electrical configuration of PLC1. As shown in FIG. 4, the basic unit 3 includes a CPU 31, a display unit 5, an operation unit 6, a storage device 32, and a communication unit 33. The display unit 5, the operation unit 6, the storage device 32, and the communication unit 33 are each electrically connected to the CPU 31. The storage device 32 may include a RAM, a ROM, a memory card, and the like. The storage device 32 has a plurality of storage areas such as a device unit 34 and a project storage unit 35. The device unit 34 has a bit device, a word device, and the like, and each device stores a device value. The project storage unit 35 stores the project data input from the PC 2a. The storage device 32 also stores the control program for the basic unit 3. As shown in FIG. 4, the basic unit 3 and the expansion unit 4 are connected via an expansion bus 90, which is a type of communication bus. Although the communication circuit related to the expansion bus 90 is mounted on the CPU 31 in FIG. 4, it may be mounted as a part of the communication unit 33. The communication unit 33 may have a network communication circuit. The CPU 31 receives the project data from the PC 2a via the communication unit 33.

Here, the expansion bus 90 will be supplementarily described. The expansion bus 90 is a communication bus used for input / output refresh. The input / output refresh is a process of updating the device value between the basic unit 3 and the expansion unit 4. I / O refresh is performed each time the ladder program is executed (that is, every scan). Note that one scan cycle includes an I / O refresh execution period, a user program execution period, and an end processing execution period.

The expansion unit 4 includes a CPU 41 and a memory 42. The CPU 41b of the expansion unit 4b controls the field device 10 according to an instruction (device value) from the basic unit 3 stored in the device. Further, the CPU 41b stores the control result of the field device 10 in a device called a buffer memory. The control result stored in the device is transferred to the basic unit 3 by input / output refresh. Further, the control result stored in the device is transferred to the basic unit 3 according to the read instruction from the basic unit 3 even at a timing different from the input / output refresh. The memory 42 includes a RAM, a ROM, and the like. In particular, the RAM has a storage area used as a buffer memory. The memory 42 may have a buffer that temporarily holds data (eg, still image data or moving image data) acquired by the field device 10.

The CPU 41a of the expansion unit 4a that functions as a data utilization unit communicates with the PC 2b via the communication unit 43 and the cable 9b. A data utilization unit is an expansion unit that executes a data utilization application. The data utilization application includes a flow for collecting and processing control data and a dashboard for displaying the execution result of the flow. The function of collecting control data may be realized by a user program other than the data utilization application. The flow may have an arithmetic block for collecting data, an arithmetic block for executing data processing, an arithmetic block for creating display data, and the like. The dashboard has graph display parts, numerical display parts, and the like. These display components may be realized by HTML data, CSS data, Javascript® code, and the like. The collection of HTML data, CSS data, and Javascript (registered trademark) code may be referred to as a Web application. In this embodiment, the flow is realized by the flow template. The flow template is prepared in advance for each application, and has one or more calculation blocks in which parameters specified by the user are set. The dashboard is also realized by the template. The dashboard template has one or more display components to which parameters specified by the user are set. Parameters are a wide variety of information, such as dashboard names, device names, numbers, and unit variable names. The unit variable is a variable for the expansion unit 4a to hold the execution result of the flow.

● Functions realized by the CPU of the basic unit FIG. 5 shows the functions realized by the CPU 31 regarding data utilization. The execution engine 51 repeatedly executes the user program every scan cycle. The execution engine 51 may be realized by an ASIC or FPGA provided outside the CPU 31. ASIC is an abbreviation for a special purpose integrated circuit. FPGA is an abbreviation for field programmable gate array. These dedicated circuits can often execute specific data processing at a higher speed than a combination of a CPU and a program. The collection unit 52a collects the device values to be collected from the device unit 34 during the end processing period in the scan cycle, creates a data record, and stores the data record in the first buffer 37a. It is not essential to collect data during the end processing period, and the user program executed by the execution engine 51 may include a description (program code such as a trigger instruction) for collecting data. However, in the case of collecting data by end processing, there is an advantage that the user program does not need to be changed. Further, the collection cycle may be the cycle specified by the collection setting 36a. By providing the first buffer 37a, the execution engine 51 is less likely to be affected by an increase in scan time due to collection and transfer processing. The device value to be collected is specified by the collection setting 36a. The collection setting 36a may be stored in the base unit 3 by the PC 2a or the expansion unit 4a. The transfer unit 53a transfers one or more data records stored in the first buffer 37a to the expansion unit 4a via the expansion bus 90. The transfer unit 53a executes the transfer process when the communication traffic on the expansion bus 90 is free. Therefore, the transfer process is executed while avoiding the period during which the execution engine 51a is executing the input / output refresh and the period during which the data is read from the buffer memory of the expansion unit 4 according to the read instruction described in the user program. .. The communication traffic of the expansion bus 90 is monitored by the monitoring unit 54a. The compression engine 55a may compress a plurality of data records in order to shorten the transfer time of the data records. The compression engine 55a does not have to be realized by the CPU 31, and may be realized by an ASIC, FPGA, or the like. By adopting the first buffer 37a in this way, it is possible to execute the transfer process and the user program asynchronously.

● Functions of Data Utilization Unit FIG. 6 is a diagram illustrating functions realized by the CPU 41a of the expansion unit 4a.

The collection unit 52c is a function of collecting data according to the collection setting 39. The collection unit 52c can be realized by the CPU 41a executing a control program such as a user program. The collection unit 52c sets the basic unit 3 so that the basic unit 3 collects the device value specified by the collection setting 39 and transfers it to the second buffer 37b of the expansion unit 4a. The collection unit 52c may write the collection setting 36a of the basic unit 3 included in the collection setting 39 to the storage device 32 of the basic unit 3. It is desirable that the collection unit 52c and the data processing unit 73 can basically operate asynchronously. A buffer may be provided to achieve this.

The collection unit 52c may set the expansion unit 4b so that the expansion unit 4b collects the device value specified by the collection setting 39 and transfers it to the third buffer 37c of the expansion unit 4a. By providing the second buffer 37b and the third buffer 37c, even if the processing load of the data processing unit 73 fluctuates, data can be collected without being missed. The collection unit 52c may write the collection setting 36b (FIG. 7) of the expansion unit 4b included in the collection setting 39 to the memory 42b of the expansion unit 4b. Note that these setting functions may be realized by the setting unit 71. The setting unit 71 receives the collection setting 39, the processing setting 61, and the display setting 62 from the PC 2a or the PC 2b and writes them to the memory 42a. The processing setting 61 includes information and a flow (program) that defines the data processing executed for the collected data by the data processing unit 73. The display setting 62 includes a template of a dashboard (HTML data, CSS, Javascript (registered trademark) code, etc.) that provides the data processing result to the Web browser 18 through the Web server 70. The generation unit 74 creates the display data of the dashboard by substituting the data processing result into the template of the dashboard according to the display setting 62 that defines the display components of the dashboard. The display data may be, for example, HTML data, image data, CSS (cascading style sheet), Javascript (registered trademark) code, or the like. Display parts include, for example, pie chart parts, bar graph parts, line graph parts, numerical display parts, and the like. When the Web server 70 accesses the Web page of the dashboard by the Web browser 18, the Web server 70 transmits the display data of the dashboard to the Web browser 18. The Web browser 18 receives the display data and displays the dashboard.

In addition, multiple data utilization applications may be provided. In this case, the data required and the read timing may differ for each data utilization application. In this case, a subbuffer may be allocated in the memory 42a for each data utilization application. The collection unit 52c reads the data record stored in the second buffer 37b and stores the data for the first data utilization application in the first subbuffer 38a. The collection unit 52c reads the data record stored in the second buffer 37b and stores the data for the second data utilization application in the second subbuffer 38b. The collection unit 52c may read the data record stored in the third buffer 37c and store the data for the first data utilization application in the first subbuffer 38a. The collection unit 52c may read the data record stored in the third buffer 37c and store the data for the second data utilization application in the second subbuffer 38b. The data processing unit 73 reads data from the first subbuffer 38a according to the first data utilization application, executes data processing, and generates a processing result. The data processing unit 73 reads data from the second subbuffer 38b according to the second data utilization application, executes data processing, and generates a processing result. The decompression engine 75 is a function of pairing with the compression engine 55a of the basic unit 3 and the compression engine 55b of the expansion unit 4b. The decompression engine 75 decompresses the data compressed and transferred by the basic unit 3 and stores it in the second buffer 37b. The decompression engine 75 decompresses the data compressed and transferred by the expansion unit 4b and stores it in the third buffer 37c. This will alleviate the congestion of communication traffic on the expansion bus 90. The defrosting engine 75 may be realized by ASIC, FPGA, or the like. In this way, the transmission of data between the basic unit 3 and the expansion units 4a and 4b is executed via the expansion bus 90.

Data utilization There may be multiple data required for each application. In that case, a plurality of necessary data may be stored in the subbuffer while maintaining the chunk of data collected in each scan in the buffer. Further, when data is distributed to the subbuffer, a time stamp or the like may be added to each record. As shown in FIG. 16, the second buffer 37b (which may be the third buffer 37c) holds a chunk of collected data. One record contains the scan number, the timer value (timestamp), and the collected data. In this example, the collected data includes relays RL1 to RL3, devices Dev1, Dev2. The first data utilization application 1601 requires relays RL1 to RL3 among the collected data. Therefore, the scan number, the timer value, and the relays RL1 to RL3 are read from the second buffer 37b and stored in the first subbuffer 38a. The first data utilization application 1601 reads out the scan number, the timer value, and the relays RL1 to RL3 from the first subbuffer 38a to create a display screen (source data). The second data utilization application 1602 requires relays RL3, devices Dev1 and Dev2 among the collected data. Therefore, the scan number, the timer value, the relay RL3, the devices Dev1 and Dev2 are read from the second buffer 37b and stored in the second subbuffer 38b. The second data utilization application 1602 reads out the scan number, the timer value, the relay RL3, the devices Dev1 and the Dev2 from the second subbuffer 38b, and creates a display screen (source data). By utilizing the subbuffer in this way, it is possible to maintain the original data in the buffer without changing it. The original data held in the buffer can be used for other purposes.

● Functions of Expansion Unit 4b Related to Data Utilization FIG. 7 is a diagram illustrating functions realized by CPU 41b of expansion unit 4b.

The execution engine 51b executes the basic functions of the expansion unit 4b (in the case of a motion unit, execution of a motion flow, etc.). The collection unit 52b collects the data specified by the collection setting 36 from the device unit 34b at the timing specified by the collection setting 36 and stores it in the fourth buffer 37d. The transfer unit 53b reads the data record stored in the fourth buffer 37d at the timing specified by the collection setting 36 or the timing when the transfer request is received by the expansion unit 4a, and reads the data record stored in the fourth buffer 37d via the expansion bus 90. , Transfer to the third buffer 37c of the expansion unit 4a. The transfer unit 53b may transfer the data record at a timing when the communication traffic of the expansion bus 90 monitored by the monitoring unit 54 is small. The compression engine 55b compresses the data record according to the collection setting 36. That is, the transfer unit 53b may transfer the data record information-compressed by the compression engine 55b to the expansion unit 4a. The compression engine 55b may be realized by the CPU 41b, but may be realized by an ASIC or an FPGA from the viewpoint of high-speed processing and reduction of the processing load of the CPU 41b.

● Example of data record FIG. 8 shows a data record 91 written to the first buffer 37a by the collecting unit 52a. The plurality of data records 91 are examples of time series data. In this example, the collection unit 52a collects the device values of the device names Dev0, Dev1, and Dev10 from the device unit 34a for each scan cycle, and adds the collection count and the time information acquired from the timer to one data. A record is created and stored in the first buffer 37a. The collection target may be data stored in the buffer memory or device allocated to the expansion unit 4b. In this example, the first buffer 37a is a FIFO (first in, first out) type buffer. The collection count is a count value of a counter that is counted up by 1 each time one data record is collected. Since the collection count is a sequential number, it is useful for detecting missing or compressed data records.

Time information such as a time stamp is useful, for example, when displaying the data acquired by the basic unit 3 and the data acquired by the expansion unit 4b on the dashboard so as to be contrastable. Generally, the collection timing in the basic unit 3 and the collection timing in each unit 4b do not match. Therefore, in order to compare the operation of the basic unit 3 with the operation of the expansion unit 4b, information for associating the data of the basic unit 3 with the data of the expansion unit 4b is required. In general, the basic unit 3 can synchronize the time information with the expansion units 4a and 4b by synchronization between units or the like. Therefore, the basic unit 3 and the expansion unit 4b each add the time information when the data records are collected to the data records, so that the data processing unit 73 transfers a plurality of data records acquired by different units on the time axis. Can be aligned.

● Transfer Timing FIG. 9 is a diagram for explaining the transfer timing of the data record. As shown in FIG. 9, the PLC1 repeatedly executes input / output refresh, user program execution, and end processing. In order to reduce the extension of the scan cycle, the transfer process is executed avoiding the input / output refresh period. Similarly, in order to reduce the elongation of the scan cycle, the transfer process is executed avoiding the execution period of UREAD and UWRIT. UREAD is an instruction to read data from the buffer memory allocated to the expansion unit 4, and is described in the user program. Therefore, the basic unit 3 accesses the expansion unit 4 according to UREAD and acquires data from the buffer memory during the execution period of the user program. UWRIT is an instruction to write data to the buffer memory allocated to the expansion unit 4, and is described in the user program. The basic unit 3 accesses the expansion unit 4 according to UWRIT and writes data to the buffer memory during the execution period of the user program.

As shown in FIG. 9, the transfer process is performed on the expansion bus 90 during the remaining transferable period excluding I / O refresh, UREAD and UWRIT. For example, it is assumed that the collection setting 36a is set to execute the transfer process for each of five data records. In this case, the transfer unit 53a executes the transfer process after the accumulation of the five data records in the first buffer 37a is completed and at the timing when the transfer request is received by the first transferable period or the expansion unit 4a. To do.

● Change of collection settings Data collection may be performed at any time during the factory operation period, for example. In this case, the collection settings used in the morning may differ from the collection settings used in the afternoon. In this case, it would be convenient to be able to easily identify which of the plurality of data records was acquired based on the first collection setting and which data record was acquired based on the second collection setting.

FIG. 10 shows the format of the data record 91 that can be changed in the middle of the collection setting. In this example, identification information for distinguishing a plurality of collection settings is added to the data record 91. The identification information "1" corresponds to the first collection setting. In the first collection setting, the devices to be collected are Dev1 and Dev10. The identification information "2" corresponds to the second collection setting. In the second collection setting, the devices to be collected are Dev1, Dev10, and Dev11. By adopting such a format, the data processing unit 73 can divide the data processing target for each collection setting and execute the data processing. For example, the identification information "1" may correspond to the first data processing setting, and the identification information "2" may correspond to the second data processing setting. The data processing unit 73 may acquire the data processing setting corresponding to the identification information from the processing setting 61 and perform data processing on the data record according to the acquired data processing setting.

● Information compression FIG. 11 is a diagram illustrating information compression of a data record. The data record group 92a indicates a data record before information compression. Here, four relay devices RL1, RL2, RL3, and RL4 are designated as collection targets. In addition, a scan number is used as the collection count. The counter may be time information acquired by a timer or the like (example: a numerical value indicating a time interval from when a certain relay is turned on to when it is turned off). In the data record group 92a, there is no change point of the relay device between the data record of scan number "1" and the data record of scan number "2". That is, the data record with scan number "2" can be compressed (discarded or deleted). However, the relay device RL1 for the data record with scan number "3" and the relay device RL1 for the data record with scan number "1" are different. As described above, since the scan number "3" has a change point, the data record of the scan number "3" is not compressed. Since there is no change point of the relay device between the data record of scan number "3" and the data record of scan number "4", the data record of scan number "4" can be compressed. Similarly, since there is no change point of the relay device between the data record of scan number "5" and the data record of scan number "6", the data record of scan number "6" can be compressed. By executing information compression focusing on such a change point, the compressed data record group 92b is realized. Each data record constituting the compressed data record group 92b has a change point.

As shown in FIG. 16, the scan number, timer value, and relays RL1 to RL3 are read from the second buffer 37b (which may be the third buffer 37c), information-compressed, and the first subbuffer 38a. It may be stored in. During the period when there is no change point of the relay device, the scan number (example: 2), the timer value (example: 450), and the relays RL1 to RL3 (example: ON, OFF, OFF) are stored in the first subbuffer 38a. It does not have to be. When there is a change point of the relay device, the scan number (example: 3), the timer value (example: 560), and the relays RL1 to RL3 (example: OFF, OFF, OFF) are the second buffer 37b (third buffer). It may be read from (37c) and stored in the first subbuffer 38a. The first data utilization application 1601 reads out the scan number, the timer value, and the relays RL1 to RL3 from the first subbuffer 38a to create a display screen (source data).

● Example of dashboard FIG. 12 shows UI 130 of the Web browser 18. The UI 130 includes a URL input unit 131 and a dashboard display area 105. The URL assigned to the dashboard is input to the URL input unit 131. The display area 105 shows the data processing result obtained from the data to be collected by the data processing unit 73. In this example, the waveforms of the relay devices RL1 and RL2 are included. Since data records are collected every scan cycle, for example, if data collection is continued for one day, a large number of data records will be collected. The data processing unit 73 superimposes and displays a plurality of waveforms acquired for the relay device RL1 with reference to the rising edge of the relay device RL1. In this example, the timing of the fall of the relay device RL1 is deviated. For example, the data processing unit 73 may calculate the average value of a plurality of waveforms and display the waveform corresponding to the average value with a thick line. There may be a pass range dX1 for the fall deviation. The data processing unit 73 may determine that the data has passed if the timing of each falling edge is included in the pass range dX1. The data processing unit 73 may execute the same processing for the relay device RL2. However, since the rise deviation of the relay device RL2 is not included in the pass range dX2, the data processing unit 73 may determine that the relay device RL2 has failed.

When the failure occurs in this way, the CPU 41a may send an error report mail to a predetermined mail address. The error report email may include a link containing the dashboard URL. The recipient of the error report mail may click this link to start the Web browser 18, display the dashboard, and check the waveform to eliminate the cause of the error.

There is a motion unit as the expansion unit 4b. The motion unit operates the industrial machine according to the command value by the basic unit 3 and holds the operation result of the industrial machine. The command value may be, for example, the coordinates of the arm of the arm-type robot. The operation result (current value) may be the coordinates of the actual arm acquired by a sensor or the like. The expansion unit 4a may acquire the command value and the corresponding current value as time series data from the expansion unit 4b, and display the deviation between the command value and the current value on the dashboard. The data processing unit 73 may obtain the difference between the command value and the current value, and display a graph showing how the difference changes with the passage of time on the dashboard. By checking such a waveform, it will be easier for the user to determine whether the cause of the error that occurred is due to the life of the consumables or a sudden event added from the outside. For example, the waveform response may gradually delay as the end of the consumable life approaches. On the other hand, when an error occurs due to a sudden event, the waveform changes only at the time when the event occurs. Therefore, the user will be able to discover the cause of the error by observing the waveform and take countermeasures.

<Flowchart>
● Expansion unit 4a
FIG. 13 is a flowchart showing a collection process executed by the CPU 41a of the expansion unit 4a. When the specific relay device is turned on, the CPU 41a executes the following processing.

In S1, the CPU 41a (setting unit 71) sets the basic unit 3 and the expansion unit 4b. For example, the CPU 41a transfers the collection setting 36a for the basic unit 3 to the basic unit 3. The basic unit 3 stores the collection setting 36a in the storage device 32. The CPU 41a transfers the collection setting 36b for the basic unit 3 to the expansion unit 4b. The expansion unit 4b stores the collection setting 36b in the memory 42b.

In S2, the CPU 41a (data processing unit 73 or collection unit 52c) determines whether or not a predetermined amount of collected data is stored in the second buffer 37b or the third buffer 37c (first subbuffer 38a or second subbuffer 38b). To do. The predetermined amount is defined by the processing setting 61. Here, it is sufficient that the buffer specified by the processing setting 61 is confirmed, and both the second buffer 37b and the third buffer 37c are not always the confirmation targets. The CPU 41 waits until a predetermined amount of data is stored in the buffer. When a predetermined amount of data is stored in the buffer, the CPU 41a proceeds to S3.

In S3, the CPU 41a (data processing unit 73) executes data processing on a predetermined amount of data read from the buffer and obtains a data processing result. The content of data processing is defined by the processing setting 61. The data processing result is held in the memory 42a.

In S4, the CPU 41a (generation unit 74) determines whether or not there is a dashboard display request (Web access) from the Web browser 18 of the PC 2b. If there is no display request, the CPU 41a proceeds to S2 and continues data collection and data processing. If there is a display request, the CPU 41a proceeds to S5.

In S5, the CPU 41a (generation unit 74) creates the display data of the dashboard corresponding to the display request. For example, the CPU 41a creates display data by substituting the data processing result stored in the memory 42a into the dashboard template.

In S6, the CPU 41a (Web server 70) transmits the display data to the Web browser 18 of the PC 2b. As a result, the Web browser 18 of the PC 2b can display the dashboard.

● Basic unit 3
FIG. 14 is a flowchart showing a collection process executed by the CPU 31 of the basic unit 3. When the specific relay device is turned on, the CPU 31 executes the following processing.

In S11, the CPU 31 (collection unit 52a) determines whether or not the collection timing (example: every scan cycle, every time a trigger signal is input, every predetermined cycle) specified by the collection setting 36a has arrived. When the collection timing arrives, the CPU 31 proceeds to S12.

In S12, the CPU 31 (collection unit 52a) collects the data to be collected specified by the collection setting 36a from the device unit 34a and stores it in the first buffer 37a.

In S13, the CPU 31 (transfer unit 53a) determines whether or not the transfer condition specified by the collection setting 36a is satisfied. The transfer condition may be, for example, the number of data records stored in the first buffer 37a. If the transfer condition is not satisfied, the CPU 31 returns to S11 and continues collecting data. If the transfer condition is satisfied, the CPU 31 proceeds to S14.

In S14, the CPU 31 (monitoring unit 54a) determines whether or not the communication traffic of the expansion bus 90 is small. If there is a lot of communication traffic, the CPU 31 returns to S11 and continues collecting data. If the communication traffic is low, the CPU 31 proceeds to S15.

In S15, the CPU 31 (transfer unit 53a) reads a predetermined amount of data records from the first buffer 37a and transfers them to the second buffer 37b. The predetermined amount is also defined by the collection setting 36a.

● Expansion unit 4b
FIG. 15 is a flowchart showing a collection process executed by the CPU 41b of the expansion unit 4b. When the specific relay device is turned on, the CPU 41b executes the following processing.

In S21, the CPU 41b (collection unit 52b) determines whether or not the collection timing (eg, every time a trigger signal is input, every predetermined cycle) specified by the collection setting 36b has arrived. When the collection timing arrives, the CPU 41b proceeds to S22.

In S22, the CPU 41b (collection unit 52b) collects the data to be collected specified by the collection setting 36a from the device unit 34a and stores it in the fourth buffer 37d.

In S23, the CPU 41b (transfer unit 53b) determines whether or not the transfer condition specified by the collection setting 36b is satisfied. The transfer condition may be, for example, the number of data records stored in the fourth buffer 37d. If the transfer condition is not satisfied, the CPU 41b returns to S21 and continues collecting data. If the transfer condition is satisfied, the CPU 41b proceeds to S24.

In S24, the CPU 41b (monitoring unit 54b) determines whether or not the communication traffic of the expansion bus 90 is small. If there is a lot of communication traffic, the CPU 41b returns to S21 and continues collecting data. If the communication traffic is low, the CPU 41b proceeds to S25.

In S25, the CPU 41b (transfer unit 53b) reads a predetermined amount of data records from the fourth buffer 37d and transfers them to the third buffer 37c. The predetermined amount is also defined by the collection setting 36b.

FIG. 17 shows an example of a dashboard 171 for a real-time monitoring application. In FIG. 17, the operation state display 172 shows the operation state of real-time monitoring. The display switching tab 173 is a tab button display for switching to another dashboard corresponding to the application when a plurality of dashboards are set for the application. FIG. 17 shows a state in which the monitor button is pressed. In this state, when the trend tab is pressed, the dashboard switches to the trend display dashboard. When the history tab is pressed, the dashboard switches to the history view dashboard. In each display column 174a to 174g, a graph related to the item name, the margin, the measured value, the caution value, the alarm value, the determination result, and the measured value is displayed for each monitoring item. The item name, caution value, and alarm value are displayed based on the application setting data (display setting 62) of the project data 15. The measured value indicates the time width from the start timing to the end timing determined based on the start condition and the end condition of the application setting data. The margin indicates how much the measured value of the monitoring item has a margin. For example, the margin may indicate how much the measured value has a margin with respect to the alarm value or the caution value. The judgment result is a judgment result obtained based on the measured value and a valid alarm value or caution value. The determination result may indicate the status classification of the monitoring target such as normal, caution, and alarm. Even if the judgment result based on the latest measured value is normal, the judgment result may be once in the state of caution or warning in the past. In this case, a higher alert state may be maintained during a predetermined determination period from the past to the present. When the clear button in the determination display field 174f is pressed, the displayed determination result may be updated to the latest determination result. The graph associated with the measured value is a visualization of the measured value. For example, a bar graph showing the time width from the start timing to the end timing may be displayed. A line corresponding to the caution value and the alarm value may be displayed at a position corresponding to the caution value and the alarm value. For example, when the threshold line display check box of the graph display field 174 g is checked, threshold lines corresponding to valid caution values and alarm values are displayed. When the setting button of the graph display field 174g is pressed, the setting dashboard among other dashboards corresponding to the application is displayed.

FIG. 18 shows an example of a configuration dashboard 181 for a real-time monitoring application. When the setting button of the graph display field 174g in FIG. 17 is pressed, the setting dashboard 181 is displayed. In FIG. 18, the operation state display 182 shows the operation state of real-time monitoring. The monitoring state changeover switch 183 is a switch for switching between a monitoring state and a non-monitoring state for real-time monitoring. The threshold value batch setting button 184 is a button for shifting to a setting screen for collectively setting a plurality of threshold values provided for each monitoring item. In each of the input fields 185a to 185f, a monitoring check box, an item name, a start condition, an end condition, a caution value, and an alarm value are displayed for each monitoring item. A setting wizard for setting the application setting data of the project data 15 in FIG. 2 and a corresponding input field may be provided. When the add button 186a is pressed, an input line for inputting a new monitoring item is added. When the delete button 186b is pressed, the input line selected by the up / down buttons 186c is deleted. When the setting reflection button 187 is pressed, the updated setting contents are reflected in the application setting data (display setting 62). Subsequently, the dashboard 171 for the real-time monitoring application based on the updated application setting data (display setting 62) is displayed. When the cancel button 188 is pressed, the dashboard 171 for the real-time monitoring application based on the application setting data (display setting 62) is displayed without reflecting the updated setting contents in the application setting data (display setting 62). To.

FIG. 19 is a flowchart showing execution of a data utilization program for real-time monitoring processing executed by CPU 41a of the expansion unit 4a and provision of a dashboard.

In S41, the CPU 41a (collection unit 52c) monitors the device or variable corresponding to the start signal and the end signal according to the application setting data (collection setting 39). The application setting data (collection setting 39) holds the name of the device or variable used as the start signal and the predetermined value stored in the device or variable. The start timing is when the value of the device or variable changes to a predetermined value, or as shown in FIG. 18, the start condition is that the change of the device or variable is the rising edge or the falling edge. May be good. The same applies to the end signal. The CPU 41a (collection unit 52c) collects the device value to be collected specified by the application setting data (collection setting 39) by executing the data utilization program based on the application setting data (collection setting 39), and the second buffer 37c. Store as collected data in. Here, the collected data may be time series data collected at different times. In addition to the data utilization program, a collection program that executes a collection operation according to the collection setting 39 may be provided. In this case, the collection setting 39 is set according to the application setting data (processing setting 61), and the set collection setting 39 is set. The device value to be collected specified by is collected, and the collected data may be stored in the second buffer 37c.

In S42, the CPU 41a (data processing unit 73) executes the data utilization program specified by the utilization program template (processing setting 61). By executing the data utilization program, the CPU 41a (data processing unit 73) determines the time information from the timing when the start signal condition is satisfied to the timing when the end signal condition is satisfied based on the collected data (device value). .. The CPU 41a (data processing unit 73) monitors whether the device or variable set as the monitoring target satisfies the conditions such as the rising edge according to the start condition 185c in FIG. Here, the timing that satisfies the condition, that is, the timing that satisfies the condition of the start signal is monitored. Similarly, the CPU 41a (data processing unit 73) monitors whether the device or variable set as the monitoring target satisfies the conditions such as the rising edge in accordance with the end condition 185d in FIG. Here, the timing that satisfies the condition, that is, the timing that satisfies the condition of the end signal is monitored. The time information determined by the CPU 41a (data processing unit 73) may be the time width from the timing satisfying the condition of the start signal to the timing satisfying the condition of the end signal.

In S43, the CPU 41a (data processing unit 73) determines the state based on the time information determined in S42 and the determination threshold set according to the application setting data (processing setting 61). The CPU 41a (data processing unit 73) executes this determination by executing the data utilization program. The upper and lower limits of the caution value and the alarm value may be set as the judgment threshold. In this case, the CPU 41a (data processing unit 73) determines whether or not the determined time information, which is the measured value, exceeds the upper limit value. Further, the CPU 41a (data processing unit 73) determines whether or not the determined time information is below the lower limit value. The application setting data (processing setting 61) may include a flag indicating whether or not each upper limit value or each lower limit value is used as a determination threshold value. In this case, the CPU 41a (data processing unit 73) compares each upper limit value and each lower limit value in which the flag included in the application setting data (processing setting 61) is checked with the determined time information which is a measured value. By doing so, the state of the monitoring target is determined. The value of this flag can be set by the user through a UI such as a checkbox. The status to be monitored may include normal, caution, and alarm. Attention state and alarm state are distinguished based on the degree of deviation of the measured value from the normal state. The difference between the measured value in the normal state (normal value) and the measured value in the alarm state (alarm value) is larger than the difference between the measured value in the normal state and the measured value in the caution state (caution value). Therefore, the alarm value is set to a value that deviates from the normal value rather than the caution value. A caution value and an alarm value may be set as upper limit values. In this case, the CPU 41a (data processing unit 73) determines that the state of the monitoring target is "normal" when the determined time information is equal to or less than the caution value. The CPU 41a (data processing unit 73) determines the state of the monitoring target as "caution" when the determined time information exceeds the caution value and is equal to or less than the alarm value. When the determined time information exceeds the alarm value, the CPU 41a (data processing unit 73) determines the state of the monitoring target as "alarm". As a result, the analyzed data is created and saved in the memory.

A caution value and an alarm value may be set as lower limit values, respectively. In this case, the CPU 41a (data processing unit 73) determines that the state of the monitoring target is "normal" when the determined time information is equal to or greater than the caution value. The CPU 41a (data processing unit 73) determines the state of the monitoring target as "caution" when the determined time information is less than the caution value and equal to or more than the alarm value. When the determined time information is less than the alarm value, the CPU 41a (data processing unit 73) determines the state of the monitoring target as "alarm". As a result, the analyzed data is created and saved in the memory.

The caution value and the alarm value may be set by the upper limit value and the lower limit value, respectively. In this case, the CPU 41a (data processing unit 73) sets the state of the monitoring target as "normal" when the determined time information is equal to or greater than the lower limit caution value and the determined time information is equal to or less than the upper limit caution value. judge. The CPU 41a (data processing unit 73) determines the state of the monitoring target as "caution" when the determined time information is less than the upper limit alarm value and equal to or more than the upper limit caution value.
Similarly, the CPU 41a (data processing unit 73) determines the state of the monitoring target as "caution" when the determined time information is less than the lower limit caution value and equal to or more than the lower limit alarm value.
The CPU 41a (data processing unit 73) sets the status of the monitoring target as "alarm" when the determined time information is less than the lower limit alarm value or the determined time information exceeds the upper limit alarm value. judge. As a result, the analyzed data is created and saved in the memory.

The CPU 41a (data processing unit 73) may calculate a margin degree indicating how much the measured value has a margin with respect to the alarm value and the caution value. The margin may be defined, for example, to be 100 when there is sufficient margin, 50 when in the caution state, and 0 when in the alarm state. In this way, the margin may be defined so that the value changes stepwise according to the distance (difference) between the caution value and the measured value. The margin is stored in the memory 42a as the analyzed data. When the measured value exceeds the alarm value, the CPU 41a (data processing unit 73) may generate a signal indicating that the measured value exceeds the alarm value. For example, when the measured value exceeds the alarm value, the CPU 41a (data processing unit 73) changes the value of the device or variable indicating that the measured value exceeds the alarm value. A device or variable indicating that the measured value has exceeded the alarm value may be assigned as a trigger. For example, it may be assigned to a logging save trigger. As a result, the operation record of the PLC1 and the like are saved with reference to the timing when the alarm is generated.

In S44, the CPU 41a (generation unit 74) generates source data of the dashboard 171 including the time information determined in S42, the determination threshold value, and the state of the monitoring target determined in S43. The CPU 41a (generation unit 74) reflects the time information determined based on the dashboard template (display setting 62), the determination threshold value, and the determined status of the monitoring target in the variables assigned to the dashboard template (display setting 62). For example, the CPU 41a (generation unit 74) displays in the graph display field 174g in FIG. 17 a measured value indicating the time width from the timing satisfying the condition of the start signal to the timing satisfying the condition of the end signal in the form of a bar graph. Create display data as shown. The time from this time and the timing when the condition of the start signal to the timing when the condition of the end signal is satisfied may be displayed in a band shape. As a result, not only the time width but also the dashboard showing at what timing in the cycle each monitored object is operating in the control of the cycle operation is displayed. For example, the right end to the left end of the graph display field 174 g may correspond to one cycle of the monitoring target. The start position of the band (bar in the bar graph) corresponds to the timing when the condition of the start signal in one cycle is satisfied. The end position of the band corresponds to the timing when the condition of the end signal in one cycle is satisfied. Therefore, the length of the band indicates the time width.

The margin may be displayed along with the measured value. The CPU 41a (generation unit 74) creates display data (eg, HTML data) for displaying the dashboard 171 based on the variables assigned to the dashboard template (display setting 62). The CPU 41a (generation unit 74) may separately manage the screen data that is the base of the dashboard 171 and the updated data such as the measured value and the state information. In this case, the CPU 41a (generation unit 74) individually manages the screen data to which the referenced device or variable is assigned and the display target data which is the value of the referenced device or variable. The CPU 41a (generation unit 74) may create display data by periodically updating the display target data. The generation unit 74 creates display data using display target data such as collected data and / or analyzed data.

In S45, the CPU 41a (Web server 70) provides the display data to the PC 2b. The CPU 41a may display the display data on the display device of the PLC1. The display device of the PLC1 may be built in the PLC1 or may be connected to the PLC1 by wire or wirelessly. The CPU 41a (generation unit 74) may separately manage the screen data to which the referenced device or variable is assigned and the display target data which is the value of the referenced device or variable. In this case, the CPU 41a (Web server 70) selectively provides the screen data and the display target data among the display data according to the update request and the update schedule of the dashboard 171. In response to the display request of the dashboard 171, the CPU 41a (Web server 70) provides display data including screen data and display target data. The CPU 41a (Web server 70) selectively provides the updated display target data as display data in response to the display update request of the dashboard 171.

FIG. 20 shows a flowchart showing a setting process via the dashboard of real-time monitoring executed by the CPU 11 of the PC 2a.

In S51, the CPU 41a (generation unit 74) displays the dashboard 181 for setting. For example, the generation unit 74 creates display data for displaying the dashboard 181 for setting shown in FIG. 18, and the CPU 41a (Web server 70) creates display data for displaying the dashboard 181 for setting. Is provided to PC2b.

In S52, the CPU 41a (setting unit 71) accepts user input for adding / deleting / changing the monitoring target and / or setting the determination threshold value. When the CPU 41a (setting unit 71) detects that the add button 186a has been pressed, it adds an input line for setting a new monitoring target. The CPU 41a (generation unit 74) creates display data to display the dashboard 181 for setting to which an input line for setting a new monitoring target is added. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the updated dashboard 181 for setting. When the CPU 41a (setting unit 71) detects that the delete button 186b has been pressed, the CPU 41a (setting unit 71) deletes the selected input line. The CPU 41a (generation unit 74) creates display data to display the dashboard 181 for setting in which the selected input line has been deleted. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the updated dashboard 181 for setting. At this time, the selection operation to the input line by the up / down buttons 186c may be displayed. When the CPU 41a (setting unit 80) accepts the change input to each input field 185a to 185d, the CPU 41a (generation unit 74) displays the dashboard 181 for setting reflecting the change input to each input field 185a to 185d. The display data is created to be displayed, and the CPU 41a (Web server 70) provides the PC 2b with the display data for displaying the updated dashboard 181 for the setting. When the CPU 41a (setting unit 71) receives the change input to each input field 185e to 185f of the judgment threshold value, the CPU 41a (generation unit 74) is for setting reflecting the change input to each input field 185e to 185f of the judgment threshold value. Create display data to display the dashboard 181 of. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the updated dashboard 181 for setting.

In S53, the CPU 41a (setting unit 71) updates the corresponding application setting data (processing setting 61) according to the user input. When the CPU 41a (setting unit 71) detects that the setting reflection button 187 has been pressed, the CPU 41a (setting unit 71) reflects the updated setting contents in the application setting data (processing setting 61). On the other hand, when the CPU 41a (setting unit 71) detects that the cancel button 188 has been pressed, the updated setting contents are not reflected in the application setting data (processing setting 61), and the updated setting contents are discarded. The CPU 41a (generation unit 74) creates display data for displaying the dashboard 171 for the real-time monitoring application based on the application setting data (processing setting 61) without reflecting the updated setting contents. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the dashboard 171 for the real-time monitoring application.

In S54, the CPU 41a (data processing unit 73) determines the state of the monitoring target based on the time information determined for the monitoring target and the set determination threshold value according to the application setting data (processing setting 61) updated in S53. The CPU 41a (data processing unit 73) has time information determined in the same manner as S42 according to the updated application setting data (processing setting 61), a determination threshold value set according to the updated application setting data (processing setting 61), and the determination threshold value. The state of the monitoring target is determined in the same manner as in S43 based on.

In S55, the CPU 41a (generation unit 74) determines the time information determined according to the updated application setting data (processing setting 61), the determination threshold value set according to the updated application setting data (processing setting 61), and the determination in S54. Display data for displaying the monitored status of the monitoring target on the status monitoring dashboard shown in FIG. 18 is created. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the dashboard 171 for status monitoring.

FIG. 21 is a flowchart showing a dynamic change process of the monitoring target executed by the CPU 41a of the expansion unit 4a. In FIG. 21, in S61, the CPU 41a (setting unit 71) accepts user input for setting changes including addition / deletion / change of monitoring targets. When the CPU 41a (setting unit 71) detects that the add button 186a has been pressed, it adds an input line for setting a new monitoring target. The CPU 41a (generation unit 74) creates display data to display the dashboard 181 for setting to which an input line for setting a new monitoring target is added. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the updated dashboard 181 for setting. When the CPU 41a (setting unit 71) detects that the delete button 186b has been pressed, the CPU 41a (setting unit 71) deletes the selected input line. The CPU 41a (generation unit 74) creates display data to display the dashboard 181 for setting in which the selected input line has been deleted. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the updated dashboard 181 for setting.

In S62, the CPU 41a (setting unit 71) requests the CPU 41a (collecting unit 52c) to change the collection target based on the set change received. In S63, the CPU 41a (collection unit 52c) determines the timing for updating the collection target based on the request in S62. The timing at which the CPU 31a (collection unit 52a) updates the collection target may be determined based on the request of S62 via the CPU 41a (collection unit 52c). The timing for updating the collection target may be, for example, at the start of scanning immediately after receiving the change request of the collection target, or at the start of cycle control immediately after receiving the change request of the collection target. Further, "immediately after acceptance" may be determined in consideration of a predetermined period from the receipt of the collection target change request to the actual execution of the collection target change.

In S64, the CPU 41a (collection unit 52c) updates the collection target based on the update timing of the collection target determined in S63. The CPU 41a (collection unit 52c) collects the updated data collected from the collection target in association with the identification information. The identification information is information for identifying that the collected data has been updated, and may be referred to as update identification information. The CPU 41a (collection unit 52c) further collects the time information when the collected data is collected with respect to the collected data to be monitored, in association with the collected data and the identification information. This time information may be referred to as collection time information. The CPU 31a (collection unit 52a) may collect the collected data from the updated collection target in association with the update identification information. The CPU 31a (collection unit 52a) may further collect the collection time information regarding the collected data to be monitored in association with the collected data and the identification information. The update of the collection target may be executed in parallel with the collection operation without stopping the collection operation.

In S65, the CPU 41a (data processing unit 73) determines whether or not the collected data has been updated based on the identification information. If the determination result regarding the update of the collected data is not updated, the CPU 41a (data processing unit 73) proceeds to S66. In S66, the CPU 41a (data processing unit 73) determines the state of the monitoring target based on the collection time information regarding the monitoring target and the determination threshold value before the setting change. Similar to S42 in FIG. 19, the CPU 41a (data processing unit 73) determines the time information from the timing when the start signal condition is satisfied to the timing when the end signal condition is satisfied based on the collected data to be monitored, and is the same as S43. The state of the monitoring target is determined based on the time information determined in 1 and the determination threshold value before the setting change. In S67, the CPU 41a (generation unit 74) displays the measured value, which is the determined time information, the determination threshold value, and the determined status of the monitoring target on the dashboard for status monitoring shown in FIG. To create. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the dashboard 171 for status monitoring. The CPU 41a (generation unit 74) may individually manage the screen data that is the base of the dashboard 171 and the updated data such as the measured value and the state information. In this case, the CPU 41a (generation unit 74) generates display data including the measured value which is the time information determined in S67, the determination threshold value, and the determined state of the monitoring target. In response to the update request, the CPU 41a (Web server 70) provides the PC 2b with display data for displaying the dashboard 171 for status monitoring including the measured value, the determination threshold value, and the determined status of the monitoring target. The CPU 41a (Web server 70) selectively provides the updated display target data as display data to the PC 2b. Returning to S65 again, the CPU 41a (data processing unit 73) determines the update of the collected data based on the identification information.

When the determination result regarding the update of the collected data is the update, the CPU 41a (data processing unit 73) proceeds to S68. In S68, the CPU 41a (data processing unit 73) determines the state of the monitoring target based on the collection time information regarding the monitoring target and the determination threshold value after the setting change. Similar to S42 in FIG. 19, the CPU 41a (data processing unit 73) determines the time information from the timing when the start signal condition is satisfied to the timing when the end signal condition is satisfied based on the collected data to be monitored, and is the same as S43. The state of the monitoring target is determined based on the measured value which is the time information determined in 1 and the determination threshold value after the setting change. In S69, the CPU 41a (generation unit 74) displays the measured value, which is the determined time information, the determination threshold value, and the determined status of the monitoring target on the dashboard for status monitoring shown in FIG. To create. The CPU 41a (Web server 70) provides the PC 2b with display data for displaying the dashboard 171 for status monitoring. The CPU 41a (generation unit 74) may manage the screen data and the display target data individually. In this case, the CPU 41a (generation unit 74) generates display data including the measured value which is the time information determined in S67, the determination threshold value, and the determined state of the monitoring target. In response to the update request, the CPU 41a (Web server 70) provides the PC 2b with display data for displaying the dashboard 171 for status monitoring including the measured value, the determination threshold value, and the determined status of the monitoring target. The CPU 41a (Web server 70) selectively provides the updated display target data as display data to the PC 2b.

FIG. 22 is a diagram showing the collected data at the time of dynamic change of the monitoring target in the second buffer 37b (which may be the third buffer 37c) and the device value in the device unit 34a. The CPU 41a (setting unit 71) requests the collecting unit 52c to change the collection target based on the received setting change. The collection unit 52c determines the timing for updating the collection target based on this request. The collection unit 52c updates the collection target during the period from scan number 100 to scan number 101 in FIG. 22. A monitoring target is specified in the application setting data (processing setting 61). The monitoring targets before the setting change are MR001 and MR002. The monitoring targets after the setting change are MR001, MR003, and MR004. The collection target of the application setting data (collection setting 39) is defined based on the application setting data (processing setting 61). Before the setting change, the collection target 1 is MR001, the collection target 2 is MR002, and the collection target 3 is not set. After the setting is changed, the collection target 1 remains MR001, the collection target 2 is changed from MR002 to MR003, and MR004 is newly added to the collection target 3. The CPU 41a (collection unit 52c) records the scan number, the timer value, the identification flag, and the collection data corresponding to each collection target in the second buffer 37b in association with each data record 91. The CPU 41a (collection unit 52c) collects the collected data based on the determined update timing, and adds the identification information according to the update timing as the identification flag. For the collection flag, for example, the count value of the ring counter that is counted for each update may be applied.

The CPU 41a (data processing unit 73) determines whether the collected data recorded in the second buffer 37b based on the identification flag is collected based on the application setting data (processing setting 61) before the update, or the application after the update. It is determined whether the data is collected based on the setting data (processing setting 61). The identification flag is set for the collected data to be monitored when the collection target is updated. Therefore, the data processing unit 73 can distinguish between the collected data before the update and the collected data after the update based on the identification flag. The data processing unit 73 dynamically changes the application setting data (processing setting 61) applied to the collected data to be monitored based on the identification flag. As a result, the PLC1 can dynamically update the collection target without stopping the collection operation.

<Summary>
[Viewpoint 1]
As shown in FIG. 5, the CPU 31 and the execution engine 51a are examples of the first execution engine that repeatedly executes the first user program. The device unit 34a is an example of a plurality of holding means for storing or variable data accessed by the first execution engine according to the first user program. The CPU 41a is an example of a second execution engine that executes the second user program asynchronously with the scan cycle of the first user program. The expansion bus 90 is an example of a bus connecting the first execution engine and the second execution engine.

The collection unit 52a functions as a collection means for collecting data stored in the collection target holding means among the plurality of holding means according to a predetermined collection setting for each scan cycle of the first user program. The first buffer 37a is an example of a first buffer that stores time-series data collected for each scan cycle by the collecting means. The transfer unit 53a is an example of a transfer means for transferring the time-series data stored in the first buffer to the second execution engine via the expansion bus.

The data processing unit 73 is an example of processing means for processing time-series data transferred by the transfer means according to a predetermined processing setting. The generation unit 74 is an example of a generation means for generating display data for displaying the processing result of data processing on the dashboard. The Web server 70 functions as a providing means for providing display data to an external computer (eg, PC2b). By providing the first buffer 37a in this way, it becomes possible to efficiently collect and transfer the data to be monitored in the PLC1.

[Viewpoint 2]
The monitoring unit 54a is an example of a monitoring means for monitoring the traffic of the expansion bus 90. The transfer unit 53a transfers the data to the second execution engine at the timing when the traffic of the expansion bus 90 is relatively low, and transfers the time series data to the second execution engine at the timing when the traffic of the expansion bus 90 is relatively heavy. You may suppress doing. This will not interfere with the execution of I / O refresh, UREAD or UWRIT instructions through the expansion bus 90, and will suppress the extension of the scan cycle.

The monitoring unit 54a may function as a monitoring means for monitoring the priority of the information to be transferred on the expansion bus 90. In this case, the transfer unit 53a transfers the time-series data to the second execution engine at a timing when there is no information having a priority higher than the priority of the time-series data. The transfer unit 53a suppresses the transfer of the time-series data to the second execution engine at a timing when there is information having a priority higher than the priority of the time-series data. It should be noted that the information transferred by refreshing and the bus communication request by the command word are assigned high priority. On the other hand, time series data is assigned a low priority.

[Viewpoint 3]
The transfer unit 53a may execute the time-series data transfer while avoiding the period during which the first execution engine uses the expansion bus 90 to execute the input / output refresh. As a result, the input / output refresh through the expansion bus 90 will not be disturbed, and the extension of the scan cycle will be suppressed.

[Viewpoint 4]
The compression engine 55a is an example of a compression means for compressing time-series data stored in the first buffer 37a. This compression process may be executed in parallel with the first execution engine executing the first user program. The transfer unit 53a may transfer the time-series data compressed by the compression means to the second execution engine. As a result, data transfer will be performed efficiently. In particular, in the expansion bus 90, the probability of collision between other transfer processing such as input / output refresh and UREAD instruction and transfer processing for data utilization will decrease.

[Viewpoint 5]
The time-series data stored in the first buffer 37a may have a plurality of data records acquired for each different scan cycle. As shown in FIG. 11, the compression engine 55a discards one of the two data records when the two data records that are in phase with each other of the plurality of data records match. Of these, a data record that is a change point of data may be left. When three or more data records that are consecutive in time are common to each other, only one data record of the three or more data records is maintained as a transfer target.

[Viewpoint 6]
The second buffer 37b is an example of a second buffer that stores time-series data transferred by the transfer means. The CPU 41a, which is the second execution engine, is configured to refer to the time-series data stored in the second buffer 37b. By preparing the second buffer 37b in this way, it is possible to asynchronously execute the storage of the data in the second buffer 37b and the data processing in the data processing unit 73.

[Viewpoint 7]
The transfer units 53a and 53b may be configured to acquire data from the holding means (eg, device unit 34b) of the expansion unit 4b and transfer the data to the second execution engine. The third buffer 37c is an example of a third buffer that stores data acquired from the holding means of the expansion unit 4b. The second execution engine may be configured to read data from the third buffer 37c and execute data processing. As a result, the storage of data in the third buffer 37c and the data processing in the data processing unit 73 can be executed asynchronously. The transfer unit 53b may write data to the third buffer 37c via the transfer unit 53a. When the transfer unit 53a functions as a master and the transfer unit 53b functions as a slave, such a transfer process may be realized.

[Viewpoint 8]
The fourth buffer 37d of the expansion unit 4b functions as a fourth buffer for storing data acquired from the holding means of the expansion unit 4b according to a predetermined control cycle different from the scan cycle. The transfer units 53a and 53b may be configured to acquire the data of the holding means of the expansion unit 4b from the fourth buffer 37d. As a result, even in the expansion unit 4b, the operation of the execution engine 51b and the data transfer process can be executed asynchronously.

[Viewpoint 9]
As described with respect to FIG. 11, the time-series data may include a first data record and a second data record acquired at different timings. The second execution engine (eg, CPU 41a) sets the time interval between the timing when the attention bit contained in the first data record changes and the timing when the attention bit contained in the second data record changes. You may calculate.

[Viewpoint 10]
As shown in FIG. 12, the time series data may include the first waveform data and the second waveform data acquired at different timings. As shown in FIG. 12, the second execution engine (eg, CPU 41a) may match the phase of the first waveform data and the phase of the second waveform data with the reference phase. The generation unit 74 may generate display data for displaying the first waveform data and the second waveform data matched to the reference phase on the dashboard. This will allow the user to visually observe differences in waveforms and response characteristics.

[Viewpoint 11]
The data processing unit 73 may be configured to execute the first data utilization application and the second data utilization application. The collection unit 52c distributes the data for the first data utilization application among the time-series data stored in the second buffer 37b to the first sub-buffer 38a, and the time-series data stored in the second buffer 37b. Of the data, the data for the second data utilization application may function as a distribution means for distributing the data to the second subbuffer 38b. The data read timing for the first data utilization application may differ from the data read timing for the second data utilization application. In such a case, by preparing a subbuffer for each application, multiple applications will be able to acquire data at the timing that suits them, and the operating efficiency of each application will be improved.

[Viewpoints 12 and 13]
The transfer unit 53a may be configured to divide and transfer time-series data. Time-series data generally tends to be a large amount of data. If a transfer request for other high-priority information occurs while a large amount of time-series data is being transferred, another high-priority information transfer request is made again. Therefore, by subdividing the time-series data, other high-priority information transfer requests can be executed between the transfers of the subdivided time-series data. Therefore, the waiting time for the transfer request of other high-priority information will be reduced.

The transfer unit 53a may be configured to transfer time-series data in parallel with the execution of the first user program by the first execution engine. This will allow time-series data to be transferred more efficiently.

The invention is not limited to the above-described embodiment, and various modifications and changes can be made within the scope of the gist of the invention.

Claims (14)

The first execution engine that repeatedly executes the first user program,
A plurality of holding means that are devices or variables that store data accessed by the first execution engine according to the first user program.
A second execution engine that executes the second user program asynchronously with the scan cycle of the first user program,
A programmable logic controller having a bus connecting the first execution engine and the second execution engine.
A collection means for collecting data stored in the holding means to be collected among the plurality of holding means according to a predetermined collection setting for each scan cycle of the first user program.
A first buffer that stores time-series data collected for each scan cycle by the collection means,
A transfer means for transferring the time-series data stored in the first buffer to the second execution engine via the bus, and
Have,
The second execution engine
A processing means for processing the time-series data transferred by the transfer means according to a predetermined processing setting, and
A generation means for generating display data for displaying the processing result of the data processing on the dashboard, and
A programmable logic controller comprising a providing means for providing the display data to an external computer. Further having a monitoring means for monitoring the priority of the information to be transferred on the bus,
The transfer means transfers the time-series data to the second execution engine at a timing when there is no information having a priority higher than the priority of the time-series data, and is higher than the priority of the time-series data. The programmable logic controller according to claim 1, wherein the transfer of the time-series data to the second execution engine is suppressed at a certain timing of priority information. 2. The transfer means according to claim 2, wherein the transfer means executes the transfer of the time-series data while avoiding the period during which the first execution engine uses the bus to execute the input / output refresh. Programmable logic controller. Further having a compression means for compressing the time series data stored in the first buffer in parallel with the first execution engine executing the first user program.
The programmable logic controller according to any one of claims 1 to 3, wherein the transfer means transfers time-series data compressed by the compression means to the second execution engine. The time-series data stored in the first buffer has a plurality of data records acquired for each scan cycle.
When two data records that are in phase with each other in the plurality of data records match, the compression means discards one of the two data records to change the data change point in the plurality of data records. The programmable logic controller according to claim 4, wherein a data record is left. It further has a second buffer for storing the time series data transferred by the transfer means.
The programmable logic according to any one of claims 1 to 5, wherein the second execution engine is configured to refer to the time-series data stored in the second buffer. controller. The transfer means is configured to acquire data from the holding means of the expansion unit and transfer it to the second execution engine.
The programmable logic controller further
It has a third buffer that stores the data acquired from the holding means of the expansion unit.
The programmable logic controller according to any one of claims 1 to 6, wherein the second execution engine is configured to read the data from the third buffer and execute data processing. The expansion unit
It has a fourth buffer that stores data acquired from the holding means of the expansion unit according to a predetermined control cycle different from the scan cycle.
The programmable logic controller according to claim 7, wherein the transfer means is configured to acquire data of the holding means of the expansion unit from the fourth buffer. The time-series data includes a first data record and a second data record acquired at different timings.
The second execution engine calculates a time interval between the timing at which the attention bit contained in the first data record changes and the timing at which the attention bit contained in the second data record changes. The programmable logic controller according to any one of claims 1 to 8, wherein the programmable logic controller. The time-series data includes the first waveform data and the second waveform data acquired at different timings.
The second execution engine matches the phase of the first waveform data and the phase of the second waveform data with the reference phase.
One of claims 1 to 8, wherein the generation means generates display data for displaying the first waveform data and the second waveform data matched to the reference phase on the dashboard. The programmable logic controller described in item 1. The processing means is configured to execute the first data utilization application and the second data utilization application.
The programmable logic controller is
With the first subbuffer,
With the second subbuffer,
Of the time-series data stored in the second buffer, the data for the first data utilization application is distributed to the first sub-buffer, and among the time-series data stored in the second buffer, the data is described. The programmable logic controller according to claim 6, further comprising a distribution means for distributing data for the second data utilization application to the second subbuffer. The programmable logic controller according to any one of claims 1 to 11, wherein the transfer means is configured to transfer the time-series data in small portions. Claims 1 to 12 are characterized in that the transfer means is configured to transfer the time-series data in parallel with the execution of the first user program by the first execution engine. The programmable logic controller according to any one of the above. A programmable logic controller having a basic unit and an expansion unit connected to the basic unit.
The basic unit is
An execution engine that repeatedly executes the user program,
A plurality of holding means that are devices or variables that store data accessed by the execution engine according to the user program.
A collection means for collecting data stored in the holding means to be collected among the plurality of holding means according to a predetermined collection setting for each scan cycle of the user program.
A first buffer that stores time-series data collected for each scan cycle by the collection means,
A transfer means for transferring the time-series data stored in the first buffer to the data utilization unit, which is an expansion unit connected via a bus.
Have,
The data utilization unit is
A processing means for processing the time-series data transferred by the transfer means according to a predetermined processing setting, and
A generation means for generating display data for displaying the processing result of the data processing on the dashboard, and
A means of providing the display data to an external computer and
A programmable logic controller characterized by having.

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