JP6866545B2 - Data collection method - Google Patents

Description

The present invention relates to, for example, a data collection unit used for collecting data from a processing machine in a factory.

In factories that produce automobile parts, various processing machines such as molding machines, press machines, cutting machines, grinders, and automatic casting and forging machines are installed. The production information in these processing machines is centrally managed by a computer system (PC) arranged in the factory (see Patent Document 1).
The computer system receives and stores data from each processing machine via a LAN installed in the factory, and uses these data as production information.

In recent years, a huge amount of various kinds of production information has been required. For example, it may be required to retrofit a new detector or measuring instrument to a processing machine installed in a factory to add collected data. In addition, the lot guarantee requires a so-called one-piece guarantee that guarantees products one by one, and the amount of data to be collected and stored is becoming enormous.

Traditionally, various measures have been taken to collect such data. For example, data is collected via a PLC (Programmable Logic Controller), which is originally a control device. In the factory where the PLC has already been installed, the control unit of each processing machine is connected to the PLC, and the computer system controls each processing machine via LAN and PLC, but the computer system uses this route to process each processing machine. Collecting data from the machine. The computer system also collects data from detectors and measuring instruments installed in each processing machine. In this case, digital signals and analog signals are sent to the computer system via LAN on the detectors and measuring instruments. Data is collected with the function of importing.

JP-A-2002-006932

Although a PLC can input a plurality of types of signals, it is originally a control device and has many functions other than signal input and is expensive. Therefore, it is costly to lay a new PLC for data collection when a new processing machine is introduced in a factory or a factory where the PLC is not laid.

In addition, since the PLC does not have a function to store data in the internal memory, it is necessary to control the timing at which the computer system captures data from the control unit of each processing machine via the PLC and accumulate the captured data. is there. Alternatively, an SD memory card or a USB memory can be connected to the PLC and data can be transferred to the computer system via these memories, but the work becomes extremely complicated. In addition to the data via the PLC, the computer system also needs to store the data from the detector and the measuring instrument, but the data from the PLC, the digital signal from the detector, and the analog signal from the measuring instrument are stored. A function of inputting data via a LAN at a predetermined timing, processing and accumulating these signals of different types is required. Therefore, it is necessary to create a system corresponding to each computer system, and if a detector or a measuring instrument is added, the system needs to be changed, which requires a very time-consuming work.

In view of the above circumstances, an object of the present invention is to provide a data collection unit capable of collecting data from a control unit, a detector, and a measuring instrument of a processing machine at low cost and without any trouble. It is in.

In order to solve the above problems, the data collection unit according to one embodiment of the present invention includes logging data output from the control unit that controls the processing machine, and first output from the detector installed in the processing machine. An input unit that inputs digital data and an analog signal output from a measuring instrument installed in the processing machine, and a data format that converts logging data input from the input unit into a second digital data of a predetermined data format. It is converted by the conversion unit, the analog / digital conversion unit that converts the analog signal input from the input unit into the third digital data, the first digital data input from the input unit, and the data format conversion unit. A data management unit that edits the second digital data and a third digital data converted by the analog / digital conversion unit according to preset rules, and a data storage that stores the data edited by the data management unit. It includes a unit and a data communication unit that transmits data stored by the data storage unit to the outside via, for example, a network.

In the data collection unit according to one embodiment of the present invention, the logging data from the control unit, the digital data from the detector, and the analog signal from the measuring instrument are all converted into digital data of a predetermined format, edited, and stored. , The stored data is typically transmitted to the outside via a network in response to a request from the outside.

Therefore, when introducing a new processing machine in a factory or factory where PLC is not installed, this data collection unit should be inserted between the control unit, detector, measuring instrument and network of each processing machine. For example, there is no need to install a new PLC to collect data.

In addition, by inserting this data collection unit between the control unit, detector, and measuring instrument of each processing machine and the network, data can be obtained from the control unit, detector, and measuring instrument of each processing machine via the network. In the computer system to be collected, it is possible to handle these data as uniform data from the control unit, detector, and measuring instrument of each processing machine, and the computer system is on the computer system side regardless of the system configuration. You will be able to collect data at the timing of. Therefore, it is possible to collect data with the same data collection system regardless of the types of control units, detectors, and measuring instruments to be connected. In other words, in a computer system, it is not necessary to create a system corresponding to each, and it is not necessary to change the system even when a processing machine, a detector, or a measuring instrument is added.

Therefore, according to the data collection unit according to one embodiment of the present invention, it is possible to collect data from the control unit, the detector, and the measuring instrument of the processing machine at low cost and without any trouble.

In the data collection unit according to one embodiment of the present invention, the data management unit converts the first digital data input from the input unit at a predetermined timing by the data format conversion unit according to a preset rule. The second digital data and the third digital data converted by the analog / digital conversion unit were taken, predetermined data among the second digital data was deleted, and the predetermined data was deleted. The second digital data is integrated with the first and third digital data.

As a result, the data collection unit can autonomously collect data without imposing a control burden on the computer system. Further, since the predetermined data of the second digital data is deleted, that is, the predetermined predetermined data of the logging data is deleted and the deleted logging data is saved, the data to be saved. Can be reduced as much as possible.
In the data collection unit according to one embodiment of the present invention, the data storage unit stores data edited by the data management unit in a removable memory medium.
This makes it possible to collect data from the control unit, detector, and measuring instrument of a stand-alone type processing machine that does not have a network connection.

In the data collection unit according to one embodiment of the present invention, the input unit inputs the first input terminal for inputting the logging data, the second input terminal for inputting the first digital data, and the analog signal. It has a third input terminal.
This makes the task of connecting easier.

According to the present invention, it is possible to collect data from a control unit, a detector, and a measuring instrument of a processing machine at low cost and without labor.

It is a block diagram which shows the structure of the data collection unit which concerns on one Embodiment of this invention. It is the figure which conceptually showed the flow of data processing in the data management part of the data collection unit shown in FIG. It is a figure which shows the whole of the production information collection system using the data collection unit shown in FIG. It is a graph which shows an example of the production information which can be referred from the database in the production information collection system of FIG.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
<Configuration of data collection unit>
FIG. 1 is a diagram showing a configuration of a data collection unit according to an embodiment of the present invention.

As shown in FIG. 1, the data collection unit 1 includes an input unit 10, a data format conversion unit 20, an analog / digital (A / D) conversion unit 30, a data management unit 40, and a data storage unit 50. The data communication unit 60 is typically provided in one housing. Having it in one housing facilitates installation and the like. Further, the data collection unit 1 is typically a dedicated machine that does not have a keyboard, a display, or an input / output unit thereof, unlike a PC or the like.

The input unit 10 includes logging data output from the control unit 3 that controls the processing machine 2, first digital data output from the detector 4 installed in the processing machine 2, and a measuring instrument installed in the processing machine 2. The analog signal output from 5 is input. Typically, the input unit 10 inputs the first input terminal 11 for inputting the logging data, the second input terminal 12 for inputting the first digital data, and the third input terminal 12 for inputting the analog signal. The input terminals 13 of the above are separately provided (see FIG. 3).

The data format conversion unit 20 converts the logging data input from the first input terminal 11 into a second digital data in a predetermined data format, for example, a CSV (Comma-Separated Values) data format.
The A / D conversion unit 30 converts the analog signal input from the third input terminal 13 into the third digital data.

In this embodiment, the first digital data input from the second input terminal 12 is sent to the data management unit 40 as it is, but it is desired between the second input terminal 12 and the data management unit 40. A means of converting to the data format may be inserted. Further, the data management unit 40 itself may convert the data into a desired data format.

The data management unit 40 has the first digital data input from the second input terminal 12, the second digital data converted by the data format conversion unit 20, and the third digital data converted by the A / D conversion unit 30. Edit digital data according to preset rules (programs).

Typically, as shown in FIG. 2, the data management unit 40 receives the first digital data (201) input from the second input terminal 12 at a predetermined timing according to a preset rule (program). ), The second digital data (202) converted by the data format conversion unit 20, and the third digital data (203) converted by the A / D conversion unit 30 are taken. _{Then, the data management unit 40 deletes predetermined data (here, X 1} , X ₂ , X ₅ ) among the second digital data (202), and the second digital data (here, X 1, X 2, X 5) from which the predetermined data is deleted is deleted. X ₃ , X ₄ ) are integrated with the first and third digital data (Y, Z) (204). Since the second digital data is logging data in the first place, there are many unnecessary data as production information, and such unnecessary data can be deleted by the data management unit 40 before being stored in the data storage unit 50. The amount of data to be stored in the data storage unit 50 can be reduced. In particular, it is very significant for the data management unit 40 to delete unnecessary data at this stage because the amount of data to be collected becomes extremely large when the lot guarantee of the product is changed to one guarantee. In addition, when the amount of data to be stored in the data storage unit 50 is reduced in this way, the burden on the computer system side is reduced accordingly.

The data storage unit 50 stores the data edited by the data management unit 40. Typically, the data storage unit 50 stores the data edited by the data management unit 40 in the internal memory or the removable memory medium 51. The removable memory medium 51 is preferably a medium using a flash memory such as an SD memory card or a USB memory.

The data communication unit 60 transmits the data stored by the data storage unit 50 to the outside via the network. Typically, the data communication unit 60 transmits data to the LAN 7 in response to a request from the computer system 6 (see FIG. 3). Of course, the network may be wireless as well as wired.
<Configuration of production information collection system>
FIG. 3 is a diagram showing the entire production information collection system using the data collection unit 1.

As shown in FIG. 3, the production information collection system 8 is typically a data collection unit between the control unit 3, the detector 4, the measuring device 5, and the LAN 7 of each processing machine 2 installed in the factory. It is made by inserting 1. A computer system 6 is also connected to the LAN 7.

Here, the processing machine 2 is, for example, a molding machine, a press machine, a cutting machine, a grinding machine, an automatic casting and forging machine, and the like in a factory that produces automobile parts and the like. The control unit 3 is installed in each processing machine 2 to control the processing machine 2 and collect logging data from the processing machine 2. The detector 4 detects the on / off of the relay or the switch and outputs the detection result as digital data. For example, when the processing machine 2 is a molding machine, the opening and closing of the mold of the molding machine is counted by a switch and the number of times the mold is used is used as production information. Since the detector 4 is not under the control of the control unit 3 and does not pass through the control unit 3 even when it is retrofitted, it is necessary to collect data via a separate route from the control unit 3. The measuring device 5 is, for example, a device that measures temperature, pressure, and the like, and the measurement result is output as an analog signal. For example, when the processing machine 2 is a molding machine, the temperature of the mold of the molding machine is measured and the measurement result is output as an analog signal. Similar to the above, since the measuring instrument 5 is not under the control of the control unit 3 and does not pass through the control unit 3 even when it is retrofitted, it is necessary to collect data via a separate route from the control unit 3.

The computer system (PC) 6 collects data from the control unit 3, the detector 4, and the measuring device 5 installed in each processing machine 2 via the LAN 7 and the data collecting unit 1.

Further, even if a stand-alone type processing machine 2 having no network connection, that is, not connected to the LAN 7, exists in the production information collection system 8, the control unit 3, the detector 4, and the measurement of the processing machine 2 are present. Data can be collected by connecting the data collection unit 1 to the device 5. The memory medium 51 is removed from the data storage unit 50 of the data collection unit 1, the memory medium 51 is attached to a memory drive (not shown) of the computer system 6, and the computer system 6 reads data from the memory medium 51. From this, the computer system 6 can collect production information data from the stand-alone type processing machine 2.
As described above, the computer system 6 sends the accumulated data to the database 9.
<Processing by database>
For example, the database 9 installed outside the factory processes data from the above computer system 6 installed in Japan or overseas, for example.
A typical example of the data processing method by the database 9 will be described.

For example, a molding machine is installed as one of the processing machines 2 in the factory, and the identification plate 81 (registered trademark) engraved with a uniquely defined QR code (registered trademark) on the mold used in the molding machine ( (See FIG. 3) is attached. The identification plate 81 is attached not only to the mold but also to the processing machine 2 in the factory.

When the mold is attached to the molding machine, the worker in the factory uses a camera-equipped information processing device such as a tablet to attach the QR code (registered trademark) of the identification plate 81 to the molding machine and the mold. The QR code (registered trademark) of the attached identification plate 81 is recognized. After that, the recognition data corresponding to the QR code (registered trademark) recognized by the application of the information processing apparatus is sent to the database 9, and the data of the molding machine and the recognition data of the mold are linked in the database 9. As a result, it is possible to know which mold is used for the data of the molding machine, and it is possible to calculate the total number of shots of the mold.

Further, in the database 9, it can be seen from the data of the molding machine, for example, under what conditions such as temperature and pressure that the nth shot was performed. Then, for example, as shown in FIG. 4, the relationship between the time and the number of production can be known from the data in the database 9, so that, for example, the number of shots in which a defect has occurred can be known from the relationship with the time. Conditions such as temperature and pressure at the time of failure can be verified. The number of products produced can be calculated, for example, from the data of a counter that counts normal products mounted on the molding machine.
The database 9 outputs the data accumulated in this way as production information as shown in FIG. 4 in response to a request from an information processing device such as a tablet.
<Summary>

As described above, in the data collection unit 1 according to this embodiment, when a new processing machine 2 is introduced in a factory or a factory where a PLC is not laid, the control unit 3 or the detector 4 of each processing machine 2 is introduced. If the data collection unit 1 is inserted between the measuring instrument 5 and the LAN 7, it is not necessary to newly install a PLC for data collection. Further, by inserting the data collection unit 1 between the control unit 3 and the detector 4 of each processing machine 2 and the measuring instrument 5 and the LAN 7, the computer system 6 can detect the control unit 3 of each processing machine 2. The data from the instrument 4 and the measuring instrument 5 can be uniformly handled as data in a predetermined format. Moreover, the computer system 6 can collect data on a regular basis regardless of the system configuration or the like. Therefore, the computer system 6 can easily collect data regardless of the types of the control unit 3, the detector 4, and the measuring instrument 5 to be connected. That is, in the computer system 6, it is not necessary to create a system corresponding to each of them, and it is not necessary to change the system even when the processing machine 2, the detector 4, and the measuring instrument 5 are added. Therefore, the data collection unit 1 makes it possible to collect data from the control unit 3, the detector 4, and the measuring device 5 of the processing machine 2 at low cost and without any trouble.
The present invention is not limited to the embodiments described above, and various other embodiments can be realized within the scope of the technical idea.
For example, the present invention can be applied to various equipment related to quality control such as processing lines such as molding, casting, forging, pressing, and automatic machines, related equipment, and measuring instruments.
Further, in the above embodiment, the computer system is installed in the factory, but the computer system may be installed outside the factory, for example, in a remote place.

1 Data acquisition unit 2 Processing machine 3 Control unit 4 Detector 5 Measuring instrument 10 Input unit 11 First input terminal 12 Second input terminal 13 Third input terminal 20 Data format converter 30 Analog / digital (A / D) ) Conversion unit 40 Data management unit 50 Data storage unit 60 Data communication unit

Claims (4)

Input the logging data output from the control unit that controls the processing machine, the first digital data output from the detector installed in the processing machine, and the analog signal output from the measuring instrument installed in the processing machine. Input section and
A data format conversion unit that converts logging data input from the input unit into second digital data in a predetermined data format, and a data format conversion unit.
An analog / digital conversion unit that converts an analog signal input from the input unit into third digital data, and an analog / digital conversion unit.
The first digital data input from the input unit, the second digital data converted by the data format conversion unit, and the third digital data converted by the analog / digital conversion unit are set according to preset rules. Data management department to edit and
A data storage unit that stores data edited by the data management unit,
A data communication unit that transmits data stored by the data storage unit to the outside is provided.
The input unit has a first input terminal for inputting the logging data, a second input terminal for inputting the first digital data, and a third input terminal for inputting the analog signal.
The first digital data, the second digital data, and the third digital data are integrated so as to be data in one format, and are configured to be stored in the data storage unit.
Using a data collection unit that outputs the data in one format in which the first digital data, the second digital data, and the third digital data are integrated, which is stored in the data storage unit, is used. ,
A method of collecting data from a plurality of the processing machines.
The control unit, detector and measuring device of each of the processing machines are connected to each of the data collection units without the intervention of a PLC (Programmable Logic Controller), and a computer system connected to the network connects each of the data collection units. A data collection method that collects the integrated form of data from the control unit, detector and measuring instrument of each said machine through . The data collection method according to claim 1.
The first digital data is CSV format data, and is
The data format conversion unit converts the logging data input from the input unit into a second digital data in CSV format.
The analog / digital conversion unit is a data collection method for converting an analog signal input from the input unit into a third digital data in CSV format. The data collection method according to claim 1 or 2.
The data management unit has a first digital data input from the input unit, a second digital data converted by the data format conversion unit, and the analog / digital data at a predetermined timing according to a preset rule. The third digital data converted by the conversion unit is taken, predetermined data is deleted from the second digital data, and the second digital data from which the predetermined data is deleted is the first and third digital data. A data collection method that integrates with your digital data. The data collection method according to claim 1, 2 or 3.
The data storage unit is a data collection method for storing data edited by the data management unit in a removable memory medium.

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