JP4888408B2 - Process data linkage device - Google Patents

Description

  The present invention realizes cooperation between production equipment and control devices having real-time information corresponding to changes in the real world and production management systems having management information updated in response to human decision-making cycles. It is related with the apparatus which performs.

  There is a DCS (Distributed Control System) that is widely used in the process industry as a mechanism for connecting individually distributed production facilities and control devices through a network and controlling them as a whole. In addition, SCADA (Supervisory Control and Data Acquisition), which can be executed on a commercially available computer, is often used in the processing and assembly industry, and records real-time information collected from each machine or device every moment. Then, information analysis and process control are performed by a preset method.

  These automatic control systems such as DCS and SCADA have real-time characteristics that control information in the system changes in synchronism with changes in information in actual production equipment and control devices at the production site. On the other hand, the management information of the production management system that performs process management, inventory management, quality control, maintenance management, etc. is managed in a management cycle that is easy for humans to manage such as days and shifts. The internal information is updated only when the situation considered to occur.

  Information transmission means from the real-time device side to the management device side as a technology for linking production equipment and control devices that handle real-time information with production management systems that handle management information synchronized with human management cycles or decision-making cycles Most of them are realized in the DCS and SCADA. For example, real-time information such as equipment failure, production progress, and quality inspection is aggregated by a preset method and transmitted to the production management system according to preset conditions.

  As information transmission means from the production management system side to the real-time device side, there is Patent Document 1 as a technique for transmitting production instructions in particular. There, the production instruction data storage means and the expansion means, and further the model-specific data storage means, information necessary for each real-time device can be added to the production instruction.

  Patent Document 2 discloses a technique for dealing with differences in individual communication specifications of real-time devices. There, a device having standardized conversion means is arranged between a real-time device called a production device and an external management device called a device management server, so that the communication specifications of different real-time devices can be individually handled. Side system development costs can be reduced.

On the other hand, there is Patent Literature 3 as a technique for changing the work instruction content according to the field situation. This is a technology on the production management system side, and does not consider real-time characteristics, but by receiving information from the real-time device and changing the production instruction contents based on the result, the real-time device and the production management system It can be said that the two-way information exchange mechanism.
JP 2002-140394 A JP 2003-58219 A JP 2007-233780 A

  In order to transmit the management information and production instruction information of the production management system to the production equipment and control equipment and realize the requested production, the management information is made more specific, and the granularity that the production equipment and control equipment can understand. It is necessary to convert the necessary information into control information added as necessary, and send it to the production facility or control device after waiting for the necessary situation. In other words, in order to actually operate production equipment and control equipment, it is necessary to set the values of the control items that the production equipment and control equipment have independently at the timing according to the production form that each factory has. is there.

  As described above, in order to link the production facility and its control device and the production management system bidirectionally using a communication network, an event for identifying the occurrence of various events is used to some extent. It is desirable to have an intermediate mechanism that is synchronized with the decision-making cycle of the management system while ensuring real-time performance. Further, the information transmission path and timing at that time are required to be dynamically determined depending on the target production method and production environment.

  In order to solve this problem, an object of the present invention is to obtain a device for bidirectionally linking control information of a production facility or control device and management information of a production management system corresponding to various situations. And

  In order to achieve the above object, the present invention includes a process control data management procedure 10, a process management data management procedure 20, a data structure management procedure 00, and a data linkage management procedure 70, and the process management data management The procedure 20 and the data structure management procedure 00 mediate the process control data 11 managed by the process control data management procedure 10 and the process management data 21 managed by the process management data management procedure 20.

  The process control data management procedure 10 is necessary for cooperation with a production management system or another control system having a different work area from real-time information 81 that changes every moment of a real-time device 80 such as a machine or a control device. An item is extracted, an identifiable name is given to the control information selected there, and the relationship between the content and the real-time information 81 can be expressed and managed as the process control data 11.

  The process management data management procedure 20 is necessary for executing management procedures relating to process management, inventory management, quality management, and maintenance management performed by the external management apparatus 90 that performs individual management for each production management system and work area. The external management information 91 item or the management item to be used independently is extracted, an identifiable name is given to the selected management information, and the relationship between the content and the external management information 91 is expressed. Management data 21 can be managed.

  Each of the process control data 11 and the process management data 21 may have a data structure in a table format.

  The data structure management procedure 00 manages the relational expression table 51 that is required to be always established between the item of the process control data 11 and the item of the process management data 21, and the process at the time of actual production execution. A status management procedure 50 for monitoring the contents of the control data 11 and the process management data 21 and constantly maintaining the relation in the relational expression table 51 by changing the contents of the process management data 21; A process data update procedure 60 which manages the update formula table 61 describing a method of changing the contents and is activated by the action management procedure at the time of actual production execution and changes the process management data 21 according to the update formula table 61. .

  The data linkage management procedure 70 manages an event definition table 72, which is a definition when the contents of the process control data 11 and the process management data 21 are in a state suitable for a specific condition, and performs actual production execution. Event management means 71 that monitors the occurrence of an event at the time, and an action management procedure 74 that manages an action definition table 75 that defines the relationship between an event and an action and executes an action in response to the occurrence of the event.

The state management procedure 50 finds a relational expression that is required to be always established between the information item of the process control data 11 and the information item of the process management data 21, and the contents of the relational expression and the relational expression are established. If a relational expression table 51 that describes information items that can be corrected is managed as a solution to the case where no such relational expression is satisfied during actual production execution, the definition is defined in advance. The information item can be corrected immediately according to the contents of the information .

  Each relational expression included in the relational expression table 51 has one modifiable information item included in the process management data 21 as a left-side information item, and is included in the process control data 11 or the process management data 21. It has other information items as right-side items, the relational expression is composed of the left-side item and one or more right-side items, and the relation defined by the relational expression is established for the values of the information items constituting the relational expression. If not, the relational expression can be established by updating the value of the process management data 21 corresponding to the left side information item.

  The process data update procedure 60 is included in the information item to be changed and the process control data 11 or the process management data 21 as a method of changing the contents of the process management data 21 in response to a situation assumed in advance. An identification name is set for the combination of update formulas configured by the information items to be managed, and the update formula table 61 describing the identification name and the contents of the update formula is managed. When the update request is received, the contents of the process management data 21 can be updated according to the contents of the corresponding update formula in the update formula table 61.

  Each update formula included in the update formula table 61 has one modifiable information item included in the process management data 21 as a left-side information item, and is included in the process control data 11 or the process management data 21. It has other information items as right-side items, the update formula is composed of the left-side items and one or more right-side items, and the process data corresponding to the left-side items is calculated from the process data corresponding to the right-side items. Can be assigned to

  In the event management procedure 71, when the contents of the process control data 11 and the process management data 21 are in a state suitable for specific conditions, or when specific information is received from the real-time device 80 or the external management device 90. When the event is received, the event is defined as an event, an identification name is set for the event, and the event definition table 72 describing the identification name and the event occurrence condition is managed. When a situation occurs, an occurrence event having the identification name and the occurrence time can be generated, and the contents can be set in the event list 73.

  The action management procedure 74 includes an identification name of an event included in the event definition table 72, the real-time data writing procedure 31, the real-time data reading procedure 32, the process management data notification procedure 41, and the process management data inquiry procedure. 42, one or more actions corresponding to the event are set from the process data update procedure 60 and other procedures, and an action definition table 75 in which the correspondence between the event and the action is described as an execution rule is managed. During actual production execution, the occurrence event set in the event list 73 is monitored, and when an applicable execution rule exists, the action identification name and request time according to the content of the execution rule are displayed. Set it in the action list 76 and change the contents of this list , It is possible to perform the actions that have been predefined.

  Each of the event definition table 72 and the action definition table 75 can have a data structure in a table format.

  The real-time data communication procedure 30 includes a real-time data writing procedure 31, a real-time data reading procedure 32, and a real-time data synchronization procedure 33 as means for communicating between the real-time information 81 and the process control data 11.

  The real-time data writing procedure 31 sets an identification name in advance for a specific changing method for the value of the real-time information 81, manages the writing procedure table 34 describing the identification name and the contents of the changing method, In actual production execution, when there is a write request using the identification name, calculation is performed with reference to the contents of the process control data 11 and the process management data 21 according to the contents of the write procedure table 34. The value to be written can be written in the real-time information 81 and the value of the process control data 11 can be changed together with the result.

  In the real-time data reading procedure 32, an identification name is set in advance for a specific reading method for the value of the real-time information 81, and the reading procedure table 35 describing the identification name and the content of the reading method is managed. When a read request is made using the identification name during production execution, the content of the real-time information 81 included in the real-time device 80 is read according to the content of the reading procedure table 35, and the value is read as the real-time information 81. Can be set in the process control data 11 corresponding to.

  In the real-time data synchronization procedure 33, when the value of the real-time information 81 has a specific change, it is decided in advance that the real-time device 80 will notify the content, and the synchronization procedure table 36 describing the content of the agreement is prepared. When the contents notified by the real-time device 80 are received according to the contents of the agreement in accordance with the change of the real-time information 81 at the time of actual production execution, the contents of the process control data 11 corresponding to the contents are received. Can be updated.

  The external management data communication procedure 40 includes a process management data notification procedure 41, a process management data inquiry procedure 42, and a process management data reception procedure 43 as means for communicating between the external management information 91 and the process management data 21. And have.

  In the process management data notification procedure 41, an identification name is set in advance for a specific notification method for notifying the external management device 90 of the contents of the process management data 21 or the process control data 11, and the identification name and notification are notified. The notification procedure table 44 describing the contents of the method is managed, and information can be notified according to the contents of the notification procedure table 44 when a notification request is made using the identification name during actual production execution. .

  In the process management data inquiry procedure 42, an identification name is set in advance for a specific inquiry method for inquiring the external management information 91 of the external management apparatus 90, and the identification name and the contents of the inquiry method are described. When the procedure table 45 is managed and an inquiry request is made using the identification name in actual production execution, information is inquired according to the contents of the inquiry procedure table 45, and the result is stored in the process management data 21. Can be set.

  In the process management data reception procedure 43, when the value of the external management information 91 of the external management device 90 is changed, it is determined in advance that the content is notified, and the identification name of the external management device 90 is determined. And the reception procedure table 46 in which the information item names of the external management information 91 are described. When the information is received from the external management device 90 at the time of actual production execution, the reception procedure table 46 is in accordance with the contents of the reception procedure table 46. The contents of the process management data 21 can be changed.

  In many cases, a plurality of control systems distributed in a factory, or between a control system and a management system are connected by a patterned decision made by a worker at a production site. In the present invention, by using the data structure management procedure and the data linkage management procedure, it is possible to provide an apparatus that substitutes for the patterned decision making of the worker on the production site. Integration of production facilities and control devices with production management systems becomes easy.

  Workers at the production site, production engineers, and process managers need knowledge about coordination between control systems or between a control system and a management system, but most of them are managed personally. In the present invention, by using the data structure management procedure and the data linkage management procedure, it is possible to provide an apparatus that describes and uses knowledge for linkage between control systems or between a control system and a management system. , It is easy to organize and accumulate those knowledge.

  Hereinafter, three embodiments of the present invention will be described with reference to the drawings.

  The first embodiment is an example relating to quality control, and its sequence chart is shown in FIG. In this example, the temperature of three locations, which are real-time data in the heat retaining device 120, is checked every 10 seconds in advance, and a warning is transmitted to the quality control PC 130 when any one of them exceeds the set maximum temperature. is there.

  In the process management data management procedure 20 for this purpose, as the process management data 21 (FIG. 7), the temperature 01 reference value (TEMP-01-MAX), the temperature 02 reference value (TEMP-02-MAX), and the temperature 03 reference A value (TEMP-03-MAX), a temperature 01 condition determination (TEMP-01-CHECK), a temperature 02 condition determination (TEMP-02-CHECK), and a temperature 03 condition determination (TEMP-03-CHECK) are set. . Further, as the process control data 11 (FIG. 6), a 10 second timer ($ TIMER), a heat retaining device temperature 01 ($ TEMP-01), a heat retaining device temperature 02 ($ TEMP-02), and a heat retaining device temperature 03 ( $ TEMP-03). The first 10-second timer corresponds to real-time data that the timer device 110 has, and the last three data correspond to real-time information 81 that represents three temperatures of the heat retaining device 120.

  Then, C001, C002, and C003 are set as equations for determining abnormality of three temperatures in the relational expression table 51 (FIG. 8) of the state management procedure 50 in the data structure management procedure 00. These relational expressions are obtained when the temperature of the heat retaining device 120 set in the process control data 11 (FIG. 6) is higher than the reference value set in the process management data 21 (FIG. 7). 21 is a logical expression that sets the condition determination set in 21 (FIG. 7) to true. For example, the relational expression C001 is a logical expression of “temperature 01 condition determination = logical expression (thermal insulation device temperature 01> temperature 01 reference value)”, and the temperature 01 when the thermal insulation device temperature 01 is larger than the temperature 01 reference value. The condition determination (TEMP-01-CHECK) is set to true. Otherwise, the temperature 01 condition determination (TEMP-01-CHECK) is set to false.

  The left side of these relational expressions is immediately recalculated whenever the value of the process management data 21 (FIG. 7) or the process control data 11 (FIG. 6) included in the right side is set or updated.

  In the synchronization procedure table 36 (FIG. 12) used by the real-time data communication procedure, the synchronization for the 10-second timer ($ TIMER) is set as S001. Here, the corresponding timer device 110 checks the change of the value every 0.001 seconds. If the value changes by 10 (seconds) or more, the timer device 110 sends the process data cooperation device 100 to the process data cooperation device 100. Sending the value of the timer at that time means that they are synchronized.

  Next, in the data linkage management procedure 70, four types of events are set in the event definition table 72 (FIG. 16) managed by the event management procedure 71. First, there is a 10-second timer event definition (E001) indicating that data corresponding to the 10-second timer ($ TIMER) as the process control data 11 (FIG. 6) is transmitted from the timer device 110. This is literally an event that occurs once every 10 seconds. Then, the temperature 01 condition determination (TEMP-01-CHECK), the temperature 02 condition determination (TEMP-02-CHECK), and the temperature 03 condition determination (TEMP-03-CHECK), which are the process management data 21 (FIG. 7), are true. There are a temperature 01 abnormal event definition (E002), a temperature 02 abnormal event definition (E003), and a temperature 03 abnormal event definition (E004) indicating that the set temperature has been exceeded.

  In the action definition table 75 (FIG. 17) managed by the action management procedure 74, first, as A001, a procedure for obtaining temperature data of the heat retaining device 120 when an event corresponding to the 10-second timer event definition (E001) occurs. Define In addition, as A002, A003, and A004, when the temperature keeping device temperature 01 ($ TEMP-01), the temperature keeping device temperature 02 ($ TEMP-02), and the temperature keeping device temperature 03 ($ TEMP-03) exceed the set temperature, That is, when a temperature 01 abnormality event (E002), a temperature 02 abnormality event (E003), and a temperature 03 abnormality event (E004) occur, a procedure for notifying the quality management PC 130 of each abnormality is defined.

  The contents of the real-time data reading procedure 32 that is an action item of the action definition A001 are set in FIG. The real-time data reading procedure corresponding to the action definition A001 is M001 in the reading procedure table 35 (FIG. 11), and the heat retaining device temperature 01 ($ TEMP-01) as the process control data 11 (FIG. 6) is transmitted from the heat retaining device 120. It indicates that the real-time data corresponding to the heat retaining device temperature 02 ($ TEMP-02) and the heat retaining device temperature 03 ($ TEMP-03) is read and the value is set in the process control data 11.

  As an execution procedure corresponding to the action definitions A002, A003, and A004, K001, K002, and K003 that are process management data notification procedures 41 are set. As shown in FIG. 13, these process management data notification procedures 41 notify the external management device 90 when an abnormality occurs. Here, any one of the heat retaining device temperature 01 ($ TEMP-01), the heat retaining device temperature 02 ($ TEMP-02), and the heat retaining device temperature 03 ($ TEMP-03) representing the temperature according to each abnormal part, This indicates that the value ($ TIMER) of the 10-second timer that is the measurement time is transmitted to the quality management PC 130.

  FIG. 18, FIG. 19, and FIG. 20 show the results of actually starting the process data linkage apparatus 100 after performing the above settings. First, at 9:00:00, a timer synchronization request is received from the timer device 110 by the real-time data synchronization procedure, and the value of the 10-second timer ($ TIMER) is changed. Further, since this reception fact is an event corresponding to the 10-second timer event definition (E001), the event management procedure 71 sets the corresponding event R001 in the event list 73 (FIG. 18).

  In the generated event R001, in the action management procedure 74, an action N001 corresponding to A001 in the action definition table 75 (FIG. 17) is generated and set in the action list 76 (FIG. 19). According to the action item in the action definition A001, the real time data reading procedure M001 is executed by the action management procedure 74, and the heat retaining device temperature 01 ($ PART-01), the heat retaining device temperature 02 ($ PART-02), and the heat retaining device temperature 03. As temperatures for ($ PART-03), 40 ° C., 35 ° C., and 50 ° C. were read, respectively, and the process control data 11 (FIG. 6) was updated.

  When the values of the warmer temperature 01 ($ PART-01), the warmer temperature 02 ($ PART-02), and the warmer temperature 03 ($ PART-03) are updated, the state management procedure 50 is performed in the data structure management procedure 00. Is activated, and the temperature 01 condition determination (TEMP-01-CHECK), the temperature 02 condition determination (TEMP-02-CHECK), and the temperature 03 condition determination (TEMP-03-CHECK) are recalculated using the relational expressions C001, C002, and C003. To do. At this time, since none of the temperatures exceeds the set temperature, all of them become false, and the process data linkage apparatus 100 once enters a standby state.

  Subsequently, at 9:00:10, an event occurs due to the reception of the 10-second timer ($ TIMER) synchronization request from the timer device 110 again, and the heat retaining device 120 at that time is processed in the same procedure. Read the temperature at three locations. The values of the heat retaining device temperature 01 ($ TEMP-01), the heat retaining device temperature 02 ($ TEMP-02), and the heat retaining device temperature 03 ($ TEMP-03) are 45 ° C., 42 ° C., It was 60 ° C. Based on this result, the temperature 01 condition determination (TEMP-01-CHECK), the temperature 02 condition determination (TEMP-02-CHECK), and the temperature 03 condition determination (TEMP-03-CHECK) are performed by the state management procedure. Recalculated and the value of the temperature 02 condition determination (TEMP-02-CHECK) became true. This is because the reference value (TEMP-02-MAX) of the temperature 02 is set to 40 ° C. in the process management data 21 (FIG. 7).

  When the value of the temperature 02 condition determination (TEMP-02-CHECK) becomes true, the event management procedure 71 applies the temperature 02 abnormal event (E003) set in FIG. 16, and the event R003 occurs. . In response to the event occurrence, the action management procedure 74 executes the action N003 corresponding to the action definition A003. This N003 is to notify the quality control PC 130 of the abnormality of the temperature 02 in accordance with K002 of the process management data notification procedure 41 of FIG. 13, and according to this procedure, the temperature maintaining device temperature 02 ($ TEMP-02) and the 10-second timer The value of ($ TIMER) is transmitted to the quality management PC 130 by the process management data notification procedure 41.

  As described above, in the first embodiment, the value of the real-time information of the real-time device called the heat retaining device 120 is not always checked, but the value is updated by communicating with the real-time device when the set event occurs. When the notification from the timer device 110 is received can be defined by a real-time data synchronization procedure, and the occurrence of an event can be limited according to the notification content, and thus the number of times of communication with the real-time device can be limited. Can be saved. In addition, since the type of real-time information to be read can be set individually, the amount of communication performed once can be reduced.

  In the first embodiment, the process control data 11 (FIG. 6) corresponding to the real-time information of the heat retaining device 120 is monitored, and the preset process data linkage apparatus 100 is only when the value meets the preset condition. This information is notified to the quality control PC 130. In other words, it was possible to sort out an enormous amount of real-time information and transmit only necessary information to the management device at the necessary timing. The notification destination and the notification method can be arbitrarily set by the process management data management procedure 20. As a result, the external management apparatus corresponding to the quality management PC 130 can handle only when a situation of interest occurs, and the internal processing logic can be simplified.

  In the first embodiment, as the real-time data synchronization procedure in the real-time data communication procedure 30, the value is changed as a condition for determining the timing of data transmission from the real-time device to the process data cooperation device 100. Various methods can be used to specify the timing for taking the time, such as a method for scheduling in advance, a condition setting based on an absolute value, a relative value, and a range of values, and a method for determining by looking at trends over a certain period.

  As a second embodiment, examples of utilization in process management and inventory management will be described below. This is because the number of necessary parts is calculated in response to the production instruction issued from the process management PC 230, and the quantity of the parts is present on the transfer device 210, and the processing device 200 is ready for operation. After confirming that it exists, the execution of the processing apparatus 200 is instructed. When the processing of the processing apparatus 200 is completed, the process data linkage apparatus 100 reads the completed lot ID and the completed quantity, and transmits a result report message to the process management PC 230 based on the content.

  For the second embodiment, in the process management data 21 (FIG. 7), a production start instruction (PROD-EXEC), a production instruction reception (ORDER-READY), and a process management PC 230 that are used for giving a production instruction. Input item NO (ITEM-ID), input lot ID (LOT-ID), input production quantity (QUANTITY), and cumulative production quantity (QUANTITY-SUM for counting the cumulative production quantity used for data input from ), A component 01 required amount (PART01-QTY) for calculating a required amount of the component, a component 02 required amount (PART02-QTY), and a component for configuration information received from the design management PC 220 as BOM information of the product 01 component number (PART01-BOM), part 02 component number (PART02-BOM), and parts at the time of production execution Parts 01 ready for indicating presence / absence (PART01-READY), parts 02 ready (PART02-READY), production possible state (MCN-READY) indicating the respective states of the processing apparatus 200, and production start state ( MCN-START) and production completion state (MCN-COMPLETE) are set.

  Further, as the process control data 11 (FIG. 6), a part 01 quantity ($ STOCK-01) and a part 02 quantity ($ STOCK-02) corresponding to real-time data indicating the quantity of parts on the transporting device 210, and processing A part 01 input amount ($ PART01-SET), a part 02 input amount ($ PART02-SET), an instruction item NO ($ ITEM-ID), and instructions, which are real-time data for writing production instructions on the apparatus 200 Lot ID ($ LOT-ID), indicated production number ($ QUANTITY), actual lot ID ($ LOT-ID-RESULT) corresponding to actual result at the time of completion of production of the processing apparatus 200, and actual production number ($ QUANTITY) -RESULT), and the processing device state ($ MCN-STATE) corresponding to the state of the processing device 200 and the processing device 20 Setting the processing device activation corresponding to the write information for the start of production ($ MCN-EXEC).

  Among the process control data 11 (FIG. 6), the machining device state ($ MCN-STATE) and the machining device activation ($ MCN-EXEC) are on the machining device 200 according to the designation of the synchronization procedure table 36 (FIG. 12). Synchronized with actual data. That is, the value of the processing device state ($ MCN-STATE) of the process data linkage device 100 automatically changes as the processing device 200 changes in status such as a production ready state, a production start state, and a production completion state. To do. Similarly, the part 01 quantity ($ STOCK-01) and the part 02 quantity ($ STOCK-02) corresponding to the quantity of the parts 01 and 02 in the transport device 210 are linked in conjunction with the actual quantity change. Will be changed.

  The contents of the relational expression table 51 (FIG. 8) include a relational expression C004 and a relational expression C005 for representing the required amount of parts, and a relational expression C006 for expressing whether or not only the required amount of parts actually exists in the transfer device 210. , Relational expression C007, relational expression C008, relational expression C009, relational expression C010, production for representing whether the state of the processing apparatus 200 is a production possible state, a production start state, or a production completion state, respectively. There is a relational expression C011 for representing whether all conditions for execution are satisfied.

  In the second embodiment, events to be recognized are defined in FIG. The contents of the corresponding event table include a production instruction reception event definition (E005) that is reception of an input item NO corresponding to reception in the production instruction message, and a production instruction execution event corresponding to a condition for executing the production instruction. There is a definition (E006), a production start event definition (E007) indicating that the processing apparatus 200 has actually started production, and a production completion event definition (E008) indicating that the production of the processing apparatus 200 has actually been completed.

  The actions to be taken when each of the above events actually occurs are defined in FIG. First, in the action definition A005, as a procedure to be performed when the work instruction message in the production instruction reception event definition (E005) is received, the process management data inquiry procedure 42 set as Q001 in the inquiry procedure table 45 (FIG. 14). The required amount of parts is inquired according to the above, and the value of production instruction reception (ORDER-READY) is set to true according to the process data update procedure set as L001 in the update formula table 61 (FIG. 9).

  Further, the action definition A006 corresponding to the production instruction execution event definition (E006) is actually executed in accordance with the real-time data writing procedure W001 in the writing procedure table 34 (FIG. 10) when the conditions for production execution are satisfied. The processing apparatus 200 is instructed to start production, and then the value of production instruction reception (ORDER-READY) is returned to false according to the process data update procedure set in L002 of the update formula table 61 (FIG. 9).

  Further, in the action definition A007 corresponding to the production completion event definition (E008) indicating the production completion in the processing apparatus 200, first, in response to the production completion notification, first, the real-time data reading procedure M002 in the reading procedure table 35 (FIG. 11). The production lot ID ($ LOT-ID-RESULT) and the production quantity ($ QUANTITY-RESULT) are read from the processing apparatus 200. Then, after calculating the cumulative production quantity (QUANTITY-SUM) by the update formula L003 of the update formula table 61 (FIG. 9) of FIG. 9, K004 of the process management data notification procedure 41 in the notification procedure table 44 (FIG. 13). The completed lot ID ($ LOT-ID-RESULT), production quantity ($ QUANTITY-RESULT), and cumulative number (QUANTITY-SUM) are notified to the process management PC 230.

  The first trigger in the second embodiment is reception of a production instruction message from the process management PC 230. For this reason, the process data linkage apparatus 100 can input the input production NO (ITEM-ID) according to the reception procedure table 46 (FIG. 15) so that the process management data 21 (FIG. 7) can be written from the process management PC 230. Regarding the input lot ID (LOT-ID) and the input production quantity (QUANTITY), the change acceptance from the process management PC 230 is permitted.

  The execution results when Example 2 is implemented are shown in FIG. 18, FIG. 19, and FIG. Here, there are five related actors: a process management PC 230, a design management PC 220, a process data linkage apparatus 100, a transfer apparatus 210, and a processing apparatus 200. Here, a production instruction message is transmitted from the process management PC 230 to the process data linkage apparatus 100 at 9: 20: 0. In the production instruction message, 1 is set as the input item number, LOT01 as the input lot ID, and 10 as the input quantity.

  In response to the message from the process management PC 230, the process data linkage apparatus 100 changes the message transmission source and the items of the process management data 21 (FIG. 7) according to the process management data reception procedure 43 into the reception procedure table 46 (FIG. 15). And the received data is set in the process management data 21 (FIG. 7). At the same time, since the input item NO is received, the event management procedure generates an event R004 corresponding to the production instruction reception event (E005) in the event table in the event list 73 (FIG. 18). Correspondingly, the action management procedure sets the action N004 corresponding to the action definition A005 in the action list 76 (FIG. 19).

  In the action management procedure 74, unexecuted actions in the action list 76 (FIG. 19) are further executed one by one. In the action N004, two action items in the action definition A005 are set. First, as the first action item, the number of component 01 configurations (PART01-BOM) and the number of component 02 configurations (PART02-BOM) corresponding to the designated input item NO (ITEM-ID) are given to the design management PC 220. Inquire. For the inquiry, the value 1 of the input item NO (ITEM-ID) as a key is transmitted. As a result, a response is received from the design management PC 220 at 9: 20: 5, and the process management data 21 (FIG. 7) is 1 for the number of parts 01 (PART01-BOM) and 4 for the number of parts 02 (PART02-BOM). ) Is set.

  During execution of the action item, the value of the process management data 21 (FIG. 7) or the process control data 11 (FIG. 6) is changed, and the data becomes the right side of the relational expression in the relational expression table 51 (FIG. 8). If there is, the process is interrupted even in the middle of the action management procedure, the state management procedure is started, and the value on the left side of the corresponding expression is changed so that the relational expression is established. This process is performed recursively.

  In this example, since the number of components 01 (PART01-BOM) and the number of components 02 (PART02-BON) are set, the required number of components 01 (PART01-QTY) and the required number of components 02 (PART02-QTY) 10 and 40 are set, respectively, and component 01 ready (PART01-READY) and component 02 ready (PART02-READY) are set to true and false, respectively. Here, the value of the part 02 ready (PART02-READY) value is false because the required number of parts 02 (PART02-QTY) is 40, whereas the quantity of parts 02 at that time ($ STOCK) -02) is 26.

  The update action L001 is applied by the second action item in the action definition A005, and the production instruction reception (ORDER-READY) becomes true. However, although a production instruction message has been received from the process management PC 230, the process data linkage apparatus 100 has not actually instructed the processing apparatus 200 to execute at 9: 20: 5. Then, at 9: 23: 0, the conveying device 210 notifies that the value of the actual number of parts corresponding to the number of parts 02 ($ STOCK-02) has been added by 50, resulting in 76. The value of 02 quantity ($ STOCK-02) is changed to 76.

  As a result of this change, the state management procedure is started, and the value of the part 02 ready (PART02-READY) becomes true. As a result, an event R005 corresponding to the production instruction execution event definition (E006) is generated by the event information management procedure. Then, corresponding to the generated event, an action N005 corresponding to the action definition A006 of the action definition table 75 (FIG. 17) is set in the action list 76 (FIG. 19).

  In the action execution procedure, an actual production execution instruction is written into the processing apparatus 200 for the first time as an action item corresponding to the action N005. Here, in accordance with the real-time data writing procedure (W001), the designated item number ($ ITEM-ID) is 1, the designated production quantity ($ QUANTITY) is 10, the designated lot ID ($ LOT-ID) is LOT01, and the part 01 input amount. ($ PART01-SET) is set to 10, part 02 input amount ($ PART-02-SET) is set to 40, and processing device activation ($ MCN-EXEC) is set to true, and real-time data corresponding to them on the processing device 200 Is rewritten. In addition, after instructing the start of actual production, the value of production instruction reception (ORDER-READY) is set to false by the process management data update procedure 60 (L002) so as not to be activated twice by one production instruction. .

  The processing apparatus 200 starts the designated production by the real-time data writing procedure performed in action N005 as described above. The state of this execution can be known by changing the value of the machining device state ($ MCN-STATE) as the process control data 11 (FIG. 6). In the example, after an execution instruction was given at 9: 23: 0, production actually started at 9: 23: 5, and production was completed at 9:30:20. These two events are processed by the event management procedure as event data corresponding to the production start event definition (E007) and the production completion event definition (E008) in the event definition table 72 (FIG. 16) as R006 and R007, respectively. 100, and is set in the event list 73 (FIG. 18).

  Further, in the process data linkage apparatus 100, an action N006 is generated according to the action definition A007 of the action definition table 75 (FIG. 17) for the completion event R007 of the processing apparatus 200 by the action management procedure, and the action list 76 (FIG. 19). ). And the action item in action definition A007 is performed in order. First, the actual lot ID ($ LOT-ID-RESULT) and the actual production number ($ QUANTITY-RESULT) are read from the processing apparatus 200 by the real-time data reading procedure (M002), and the cumulative production number (L003) is read by the process data update procedure (L003). QUANTITY-SUM) is calculated, and finally the process management data notification procedure 41 (K004) gives the process management PC 230 the actual lot ID ($ LOT-ID-RESULT), the actual production number ($ QUANTITY-RESULT), The cumulative production quantity (QUANTITY-SUM) is transmitted and the process is terminated. The work completion time was 9:30:22.

  In the second embodiment, more information is added to the work instruction from the process management PC 230 when it is sent to the processing apparatus 200 that actually performs the production. For example, the production instruction information by the process management PC 230 is only information on the input item NO (ITEM-ID), the input lot ID (LOT-ID), and the input quantity (QUANTITY). A part 01 input amount ($ PART01-SET) and a part 02 input amount ($ PART02-SET) related to necessary parts are added. It can also be said that the instruction information is sent to the processing apparatus 200 as a result of implicitly adding information on which processing apparatus is used. The method for realizing such addition of information and the change of the route according to the situation can be handled by setting the table format without individually programming.

  In addition, in order to make the production instruction information from the process management PC 230 correspond to the actual production execution in the processing apparatus 200, the process data linkage apparatus 100 can send an execution instruction in view of the timing necessary for production execution. In the second embodiment, the rule that production can be executed unless the necessary amount of parts 01 and 02 exists is specified in a table format, so that the production is delayed until the arrival of part 02, and the execution of the part 02 is stopped. Was instructed to the processing apparatus 2000. In this way, the process data linkage apparatus 100 can monitor conditions for production execution such as the presence or absence of materials and completion of the previous process, and can transmit an execution instruction with a delay in timing until the conditions are met. It was.

  As Example 2 shows, by using the process data linkage device 100 provided by the present invention, process management for managing the progress of work, and inventory management for managing the quantity and position of materials and work-in-process, It was possible to link them dynamically at positions closer to the equipment and equipment than production management systems such as process management PCs and inventory management PCs. In particular, the linkage integration on the process data linkage apparatus 100 is superior in terms of real-time performance and reliability, not the linkage integration performed by the production management system mainly using management information used for human decision making. .

  In the second embodiment, the process data cooperation device 100 inquires the product management data to the design management PC 220 when executing production. As described above, by using the process data linkage apparatus 100 provided by the present invention, the process management PC 230 does not need to transmit all the information related to the production method when transmitting the work instruction to the process. The process data linkage apparatus 100 acquires information from the design management PC 220 as necessary, so that it is possible to reduce the setup time when performing high-mix low-volume production according to the situation.

  The third embodiment is an example of maintenance management. Here, it corresponds to the case where maintenance such as inspection is performed after a predetermined number of times of production by a specific device on the production line. In the embodiment, when the number of executions of the processing device 200 is counted and reaches 100 times, the monitoring device 300 displays to inform the worker that maintenance work is necessary.

  Maintenance work is automatically performed by the maintenance device 310, but this start is not automatically started when the number of executions reaches 100, but the worker presses the maintenance work start button for confirmation. Start at the time. Therefore, when an operator wants to carry out maintenance work later for the convenience of production or the like, production can be executed more than 100 times.

  The settings of the process data linkage apparatus 100 corresponding to the above embodiment are as follows. First, as the process management data 21 (FIG. 7) managed by the process management data management procedure 20, the number of operation times of the apparatus (MCN-CNT) for counting the number of operation times of the apparatus, and maintenance work is performed on the operator on the operation panel. A maintenance work presentation for requesting (MCN-MAINTE) and a maintenance work instruction (MCN-MAINTE-EX) for actually deciding to perform maintenance work on the maintenance device 310 are set.

  As the process control data 11 (FIG. 6) managed by the process control data management procedure 10, when maintenance work corresponding to the real-time data of the monitoring apparatus 300 is necessary, a notification that the necessity is notified to a part of the console of the apparatus Maintenance work request ($ MAINTE-NEED) for highlighting and a maintenance work button ($ MAINTE-BUTN) corresponding to ON / OFF of a maintenance work start button on the console corresponding to the display. ), And maintenance work activation ($ MAINTE-EXEC), which is real-time data of the maintenance device 310 and is an activation variable for starting the maintenance work.

  The relational expression table 51 (FIG. 8) managed by the state management procedure 50 includes a relational expression C020 for setting maintenance work presentation when the number of operation of the apparatus reaches 100 or more, and this maintenance work presentation is true. And a relational expression C013 that sets the maintenance work instruction to true when the maintenance work button indicating the state of the button for starting the maintenance work is true (pressed state) is set. According to these relational expressions in FIG. 8, when the item on the right side is always changed, the value on the left side is reset so that the expression is satisfied immediately.

  Next, in S007 of the synchronization procedure table 36 (FIG. 12) managed by the real-time data synchronization procedure 33, the maintenance operation button ($ MAINTE-BUTN) corresponding to the state of the maintenance operation start button in the monitoring apparatus 300 is linked. Define. Thus, in the monitoring apparatus 300, the value of the maintenance work button ($ MAINTE-BUTN) becomes true when the corresponding button is pressed, and immediately becomes false when released.

  In the data linkage management procedure 70, first, as the event definition table 72 (FIG. 16) managed by the event management procedure 71, a maintenance request corresponding to a case where production is performed a set number of times and maintenance work is required. An event (E009) and a maintenance execution event (E010) corresponding to a case where conditions for maintenance execution are satisfied are set.

  The action definition table 75 (FIG. 17) managed by the action management procedure 74 includes an action definition A008 for counting the number of productions, and when maintenance work is necessary, this is indicated on the monitoring device 300. An action definition A009 for displaying at a specific position and a precondition for performing maintenance work in the maintenance device 310 are prepared, and an action definition A010 for actually instructing the maintenance work is set.

  The actual movement will be described with reference to FIG. 18, FIG. 19, and FIG. First, at 10:13:40, the state of the machining apparatus 200 is completed, and the value of the corresponding machining apparatus state ($ MCN-STATE) in the process data linkage apparatus 100 is set to 2 by the real-time data synchronization procedure 33. . As a result, an event R008 corresponding to the production completion event definition (E008) in the event definition table 72 (FIG. 16) is generated, and an action N007 corresponding to the action definition A008 in the action definition table 75 (FIG. 17) is added to the action list 76 ( 19).

  As a result of the action N007, 1 is added to the number of times the apparatus is operated (MCN-CNT) by the process data update procedure 60 according to the update formula L004, and the value becomes 100 times at this point. As a result, the relational expression C012 managed by the state management procedure 50 is activated, the value of the maintenance condition determination (MCN-MAINTE) becomes true, and the maintenance request event (E009) set in the event definition table 72 (FIG. 16). Event R009 corresponding to is set in the event list 73 (FIG. 18). By this event R009, the action N008 corresponding to the action definition A009 of the action definition table 75 (FIG. 17) is set in the action list 76 (FIG. 19).

  In response to this action N008, the real-time data writing procedure 31 sets the real-time data of the monitoring device 300 corresponding to the maintenance work request ($ MAINTE-NEED) to true, and the maintenance request in the monitoring device 300 is displayed. Is called. The operator is required to see the display and press a maintenance work start button based on his / her own judgment. At this time, it is 10:13:40. After that, 10: 15: 5 was reached, and the worker pressed the maintenance work start button in the monitoring apparatus 300. This operation can be known by the real-time data synchronization procedure when the value of the maintenance work button ($ MAINTE-BUTN) in the process data linkage apparatus 100 becomes true.

  Then, the value of the maintenance work instruction (MCN-MAINTE) is set to true by the state management procedure 50, and an event R010 corresponding to the maintenance execution event definition (E010) in the event definition table 72 (FIG. 16) is generated. When this event occurs, action N009 corresponding to action definition A010 in action definition table 75 (FIG. 17) is set in action list 76 (FIG. 19).

  The action item of action N009 includes a step of instructing the start of maintenance work of the maintenance device 310 in response to the start of maintenance work ($ MAINTE-EXEC) by the real-time data writing procedure 31, and the number of times of operation of the device (MCN-CNT). A step of clearing the value to 0 and a step of turning off the maintenance work request display of the monitoring apparatus 300 corresponding to the maintenance work request ($ MAINTE-NEED) by the real-time data writing procedure 31 are included. These steps corresponding to the action item of N009 were performed in this order, and maintenance was performed at 9: 15: 5.

  In Example 3, the number of executions of the processing apparatus 200 was counted in order to perform maintenance work on equipment. This number of times is held in the process data linkage apparatus 100 without being communicated to the process management PC 230 or a maintenance PC. And action is taken only when it reaches a certain number of times. In the third embodiment, maintenance is performed as an action, but a message can be transmitted to a management PC or the like as necessary. Thus, by using the process data linkage device 100 provided by the present invention, it is possible to manage the real-time information 81 possessed by the production facility and the control device as information processed in time series.

  As the handling of time-series information, Example 3 can be expanded and each value at the time when the machining of the machining apparatus 200 is completed can be held as history information. For example, a management item in a list format corresponding to the actual lot ID ($ LOT-ID-RESULT) and the actual production number ($ QUANTITY-RESULT) is set in the process management data 21 (FIG. 7), and a time tag or event is set there. By adding tags and storing values, time-series data can be managed.

  In the third embodiment, the monitoring device 300 shows an example in which the instruction information presented by the process data linkage device 100 is coordinated with the operator's decision making. In many automated apparatuses, the apparatus is activated based on the result calculated by the computer. However, in this case, the apparatus is not activated until the operator actually presses the start button in response to the presented maintenance work start request. As described above, by using the process data cooperation device 100 provided by the present invention, various production modes can be realized in which the computer-controlled system and the human system cooperate.

  In the first to third embodiments described above, many management devices such as quality control PCs, process control PCs, and design management PCs, factory control levels, timer devices, heat retention devices, processing devices, transfer devices, maintenance devices, and monitoring devices are used. It has been shown that a control level real-time device such as a device cooperates via the process data cooperation device 100 provided by the present invention. In cooperation, the information transmission path changes according to individual circumstances and circumstances such as the object to be produced and the type of work, and at the same time, the information content also changes as necessary. Conventionally, such a response requires individual system development, but the process data linkage apparatus 100 provided by the present invention can be realized by changing the contents of various tables.

  In many factories, for security reasons, a production management system that can be connected to an external network such as the Internet and a control system that can directly control factory machines and devices are managed as separate networks. In general, a management device at a factory management level is often connected to the Internet. The process data linkage device 100 provided by the present invention is located between a management device at a factory management level and a real-time device at a control level, and manages data at each level separately. Further, the cooperation between the two must be performed through the data structure management procedure 00 or the data cooperation management procedure 70. Therefore, it is possible to prevent the management apparatus side system from directly operating the control information of the real-time device, and the security level of the factory can be improved.

  In the description of the first to third embodiments so far, the data structure management procedure 00 and the data linkage management procedure 70 have been described separately, but these can be defined as an integral unit. Further, the process data cooperation device 100 can be defined as a part of the real-time device 80 or the external management device 90.

  The field of application of the present invention is not only for factories that have production facilities and control devices and are being automated, but integrated management of the operation of production facilities and control devices such as distribution centers and outdoor production facilities. It is applicable to scenes that need to be done. In addition, the present invention can be used in many service industries that need to handle various equipment and devices in stores and event facilities, and in agriculture and mining industries where mechanization has advanced.

It is a figure showing the whole structure of this invention. It is a figure showing the structure and procedure regarding the data structure management procedure 00. FIG. FIG. 6 is a diagram illustrating a configuration and a procedure related to a data linkage management procedure 70. FIG. 2 is a diagram illustrating a configuration and a procedure related to a real-time data communication procedure 30. It is a figure showing the structure and procedure regarding the external management data communication procedure. It is a figure showing the structure 11 and example of contents of process control data. It is a figure showing the structure 21 and content example of process management data. It is a figure showing the structure of the relational expression table 51, and the example of content. It is a figure showing the structure and content example of the update type | formula table 61. FIG. 4 is a diagram illustrating a structure and an example of contents of a writing procedure table 34. FIG. FIG. 6 is a diagram illustrating a structure and example contents of a reading procedure table 35. It is a figure showing the structure and example of a content of the synchronization procedure table. It is a figure showing the structure and content example of the notification procedure table. It is a figure showing the structure of the inquiry procedure table 45, and the example of content. 5 is a diagram illustrating a structure and an example of contents of a reception procedure table 46. FIG. It is a figure showing the structure of the event definition table 72, and the example of content. It is a figure showing the structure and example of contents of the action definition table 75. It is a figure showing the structure and content example of the event list 73. It is a figure showing the structure of action list 76, and an example of contents. It is a sequence diagram of the result of having performed quality control in Example 1. FIG. It is a sequence diagram of the result of having performed production management and inventory management in Example 2. FIG. FIG. 10 is a sequence diagram of a result of executing maintenance management in the third embodiment.

Explanation of symbols

00 Data structure management procedure 10 Process control data management procedure 11 Process control data 20 Process management data management procedure 21 Process management data 30 Real-time data communication procedure 31 Real-time data writing procedure 32 Real-time data reading procedure 33 Real-time data synchronization procedure 34 Writing procedure Table 35 Reading procedure table 36 Synchronization procedure table 40 External management data management procedure 41 Process management data notification procedure 42 Process management data reference procedure 43 Process management data reception procedure 44 Notification procedure table 45 Reference procedure table 46 Reception procedure table 50 Status management procedure 51 Relational expression table 60 Process data update procedure 61 Update expression table 70 Data linkage management procedure 71 Event management procedure 72 Event definition table 73 Event list 74 Action management Procedure 75 Action definition table 76 Action list 80 Real time device 81 Real time information 90 External management device 91 External management information 100 Process data linkage device 110 Timer device 120 Thermal insulation device 130 Quality control PC
200 Processing device 210 Conveying device 220 Design management PC
230 Process management PC
300 Monitoring device 310 Maintenance device

Claims (4)

One or more real-time devices 80 that handle real-time information 81 that changes from moment to moment at a production site and one or more external management devices 90 that handle external management information 91 necessary for performing a production management procedure are connected. Process control data management that manages the process control data 11 that mediates the cooperation between the apparatuses on the network and that defines the correspondence with a part of the real-time information 81 and associates the value with the communication . A process management data management procedure 20 for managing the process management data 21 in which the correspondence relationship between the procedure 10 and a part of the external management information 91 is defined and the value is associated by communication, and the process control data 11 so as to satisfy the definition formula of the relationship at the time of setting the actual production run by definition equation between the values of the process control data 21 The data structure management procedure 00 for changing the process management data 21, and the contents of the process control data 11 and the process management data 21 are monitored and set in advance when it is determined that an event has occurred according to the event definition contents set in advance. The process data cooperation apparatus characterized by having the data cooperation management procedure 70 which performs the performed action, and performing cooperation between apparatuses of different types for each kind of situation. The data linkage management procedure 70 manages an event definition table 72 that defines what conditions the contents of the process control data 11 and the process management data 21 meet when an event occurs. Event management means 71 for monitoring the occurrence of an event at the time of production execution and the process data update procedure 60 , real-time data write procedure 31, real-time data read procedure 32, process management data notification procedure 41, or process management data inquiry procedure 42 An action management procedure 74 for managing an action definition table 75 that defines a relationship between an action to be performed and an event and executing an action specified in the action definition table 75 in response to the occurrence of the event. The process data linkage device according to 1. Wherein the data structure management procedures 00 manages the process control item as the step relation table 51 constituted always relational expression be satisfied is required between the items of the management data 21 in the data 11, the relation The relational expression of the expression table 51 includes designation of items that can be corrected, and the contents of the process control data 11 and the process management data 21 are monitored at the time of actual production execution, and the process control data 11 and the process management data 21 are monitored. if the change of the contents not related expression defined is met the relation table 51 to change the contents of the process control data 21 corresponding to the specified modifiable items in the relationship table 51 in the state management procedures 50 to always maintain the relationship of the equation table 51, it describes how to change the contents of the process control data 21 updated 3. A process data update procedure 60 that manages the table 61 and is activated by the action management procedure at the time of actual production execution and changes the process management data 21 in accordance with the update formula table 61. The process data linkage device described in 1.   As means for communicating between the real-time information 81 and the process control data 11, a real-time data writing procedure 31, a real-time data reading procedure 32, and a real-time data synchronization procedure 33 are provided. The external management information 91 and the process management A process management data notification procedure 41, a process management data inquiry procedure 42, and a process management data reception procedure 43 are provided as means for communicating with the data 21, and the real time data synchronization procedure 33 is determined by the real time device 80. 4. The process data cooperation apparatus according to claim 1, wherein the process management data reception procedure 43 is started at a timing determined by an external management apparatus 90. 5.

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