JPWO2020166004A1 - Control systems, programmable logic controllers, methods, and programs - Google Patents

Abstract

The control system (1) includes an information processing device (200) that supplies diagnostic parameters used to apply diagnostic rules for diagnosing FA devices (601, 602, 603), and FA devices (601, 602, 603). ) Is included with PLC (100) for diagnosing and controlling. The rule supply unit (260) of the information processing device (200) supplies diagnostic parameters to the programmable logic controller. The program storage unit (130) of the PLC (100) is a program including a diagnostic function block for realizing the function of the diagnostic processing, and is for executing the processing for controlling the FA devices (601, 602, 603). Memorize the control program. The execution unit (180) of the PLC (100) diagnoses FA devices (601, 602, 603) by executing a control program including a diagnostic function block in which diagnostic parameters are set, and the FA device according to the diagnosis result. (601, 602, 603) is controlled.

Description

The present invention relates to control systems, programmable logic controllers, methods, and programs.

In factories, plants, etc., which are production sites, the programmable logic controller and the host system that manages the programmable logic controller work together for the purpose of preventive maintenance of equipment, improvement of manufacturing quality, etc., in the production process, inspection process, etc. May diagnose the machinery and equipment used in the process.

Patent Document 1 describes that a host system of a field device such as a programmable logic controller generates a diagnostic rule and supplies the diagnostic rule to the field device. The field device diagnoses the device based on the diagnosis rule supplied from the host system and the data collected from the device to be diagnosed, and outputs an alert according to the diagnosis result.

JP-A-2002-062933

In the configuration described in Patent Document 1, after the field device outputs an alert according to the diagnosis result, for example, the operator needs to take necessary measures for the device. In this case, it was often the case that the worker could not take action on the device immediately after the field device output the alert. For this reason, there is a time lag between the diagnosis of the device and the control of the device.

The present invention has been made in view of the above circumstances, and an object of the present invention is to allow a programmable logic controller to control a device to be controlled immediately after diagnosing the device to be controlled.

In order to achieve the above object, the control system according to the present invention includes an information processing device that supplies diagnostic parameters used for applying diagnostic rules for diagnosing a diagnostic target, and a programmable logic controller that diagnoses and controls the diagnostic target. And include. The diagnostic rule supply means included in the information processing device supplies diagnostic parameters to the programmable logic controller. The program storage means included in the programmable logic controller is a program including a diagnostic function block for realizing a function of diagnostic processing, and stores a control program for executing a process for controlling a controlled object. The execution means provided in the programmable logic controller diagnoses the diagnosis target by executing a control program including a diagnosis function block in which diagnostic parameters are set, and controls the control target according to the diagnosis result.

In the control system according to the present invention, the information processing apparatus supplies the programmable logic controller with diagnostic parameters used for applying diagnostic rules for diagnosing a diagnostic object. The programmable logic controller diagnoses the diagnostic target by executing a control program including a diagnostic function block in which diagnostic parameters are set, and controls the control target according to the diagnosis result. In this way, the programmable logic controller can control the device to be controlled immediately after diagnosing the device to be controlled.

Functional block diagram of each device included in the control system according to the embodiment of the present invention. The figure which shows the hardware configuration of each apparatus included in the control system which concerns on embodiment. The figure which shows the example of the user program which concerns on embodiment The figure for demonstrating the structure of the program storage part and the 2nd conversion part of the programmable logic controller which concerns on embodiment. The figure which shows the example of the functional block for diagnosis which concerns on embodiment The figure which shows the example of the diagnostic parameter which concerns on embodiment Flowchart of diagnostic rule generation process according to the embodiment Flowchart of execution preparation process according to the embodiment The figure which shows the example of the function block for diagnosis which concerns on the modification The figure which shows the example of the diagnostic parameter which concerns on the modification The figure which shows the example of the other diagnostic function block which concerns on the modification The figure which shows the example of the other diagnostic parameter which concerns on the modification

Hereinafter, the control system according to the embodiment of the present invention will be described in detail with reference to the drawings.

(Embodiment)
The control system 1 shown in FIG. 1 includes a programmable logic controller 100 that controls FA devices 601 to 603, an information processing device 200 that generates diagnostic rules, and a maintenance tool 500 for a user to operate the programmable logic controller. Including.

The programmable logic controller 100 (hereinafter referred to as PLC100) is a control device that controls FA devices 601, 602, and 603 in a production system. FA devices 601, 602 and 603 are mechanical devices operating on a production line. The PLC 100 controls the FA devices 601, 602 and 603 by executing a control program. Specifically, the PLC 100 executes an operation using the values indicated by the input signals supplied from the FA devices 601, 602 and 603 by executing each instruction of the control program at each scan time which is a set cycle. Then, the output signal based on the value indicating the calculation result is supplied to the FA devices 601, 602 and 603. Hereinafter, the FA devices 601, 602, and 603 may be collectively referred to as the FA device 600.

As a characteristic configuration according to the embodiment, the PLC 100 diagnoses the FA device 600 according to the diagnostic rules supplied from the information processing device 200 during the execution of the control program, and controls the FA device 600 according to the diagnosis result. .. The FA device 600 is a diagnostic target and a control target of the PLC 100.

The information processing apparatus 200 collects data from the FA device 600 via the PLC 100 or directly, and analyzes the collected data. Further, the information processing apparatus 200 generates a diagnostic rule for diagnosing the FA device 600 based on the analysis result, and supplies the PLC 100 with a diagnostic parameter which is a parameter used for applying the generated diagnostic rule. .. The information processing apparatus 200 performs analysis and generation of diagnostic rules prior to the PLC 100 starting execution of the control program. As the information processing device 200, for example, an industrial personal computer (IPC) is used.

The diagnostic process executed by the PLC 100 is, for example, diagnosed as normal when the value indicating the calculation result is within the specified range, and diagnosed as abnormal when the value is outside the specified range. It is a thing. When the PLC 100 performs such a diagnostic process, the information processing apparatus 200 obtains an upper limit value and a lower limit value for defining a designated range from the analysis result, and supplies the obtained condition value and the lower limit value to the PLC 100 as diagnostic parameters. To do.

The maintenance tool 500 is a tool for the user to operate the PLC 100. The user creates a program necessary for controlling the FA device 600 by using the maintenance tool 500, and stores the created program in the PLC 100. Further, the user uses the maintenance tool 500 to store the data necessary for the PLC 100 and the information processing device 200 to operate in the PLC 100 and the information processing device 200, respectively. As the maintenance tool 500, for example, a personal computer in which a dedicated application installed in the same factory as the FA device 600 is installed is used. Here, the user is, for example, an administrator of PLC100.

As shown in FIG. 2, the PLC 100 has a memory 11 for storing various programs and data, a fieldbus interface 12 for communicating with other devices via the network 701, and another via the network 702 as a hardware configuration. It has an information system network interface 13 that communicates with the device of the above, and an MPU (Micro Processing Unit) 14 that controls the entire PLC 100. The memory 11, the fieldbus interface 12, and the information network interface 13 are connected to the MPU 14 via the bus 19, and each communicates with the MPU 14.

The memory 11 includes a volatile memory and a non-volatile memory. The memory 11 stores programs for realizing various functions of the PLC 100. Specifically, the memory 11 stores the collection program 111, the user program 112, and the diagnostic function block 113. Further, the memory 11 is used as a work memory of the MPU 14.

The collection program 111 is a program for realizing a function of collecting data from a designated target on the PLC 100.

The user program 112 is a program for realizing the function of controlling the control target on the PLC 100. The user program 112 is described as a ladder diagram. The user program 112 is a program created by the user.

The diagnostic function block 113 is a componentized circuit block related to diagnostic processing that is repeatedly used in the user program 112. The diagnostic function block 113 is described in the function block diagram. The diagnostic function block 113 is created by the manufacturer of the PLC 100. Two or more diagnostic function blocks 113 may be stored in the memory 11. The diagnostic function block 113 is an example of the diagnostic function block of the present invention.

In the embodiment, the user shall create a user program 112 in which the diagnostic function block 113 is incorporated, as shown in FIG. Therefore, the PLC 100 can diagnose and control the FA device 600 by sequentially executing the instructions of the user program 112.

The fieldbus interface 12 includes a network interface circuit and communicates with the information processing device 200 and the FA device 600 via the network 701 under the control of the MPU 14. The network 701 is a network conforming to the fieldbus standard.

The information system network interface 13 includes a network interface circuit and communicates with the information processing apparatus 200 and the FA device 600 via the network 702 under the control of the MPU 14. The network 702 is a network conforming to a standard such as 10BASE-T or 100BASE-T.

The MPU 14 executes various programs stored in the memory 11 to realize various functions of the PLC 100. Specifically, the MPU 14 collects data from the designated collection target by executing the collection program 111. The MPU 14 controls and diagnoses the FA device 600 by executing the user program 112 in which the diagnostic function block 113 is incorporated.

As a hardware configuration, the information processing device 200 communicates with a memory 21 for storing various programs and data, a fieldbus interface 22 for communicating with another device via a network 701, and another device via a network 702. It has an information system network interface 23 and a CPU (Central Processing Unit) 24 that controls the entire information processing device 200. The memory 21, the fieldbus interface 22, and the information network interface 23 are connected to the CPU 24 via the bus 29, and each communicate with the CPU 24.

The memory 21 includes a volatile memory and a non-volatile memory. The memory 21 stores programs for realizing various functions of the information processing apparatus 200. Specifically, the memory 21 stores the collection program 211, the analysis program 212, and the rule generation program 213. Further, the memory 21 is used as a work memory of the CPU 24.

The collection program 211 is a program for realizing a function of collecting data from a designated target in the information processing apparatus 200. The analysis program 212 is a program for realizing the function of analyzing the collected data in the information processing apparatus 200. The rule generation program 213 is a program for realizing the function of generating the diagnostic rule based on the analysis result in the information processing apparatus 200.

The fieldbus interface 22 includes a network interface circuit and communicates with the information processing device 200 and the FA device 600 via the network 701 under the control of the CPU 24. The information system network interface 23 includes a network interface circuit and communicates with the PLC 100 via the network 702 under the control of the CPU 24.

The CPU 24 executes various programs stored in the memory 21 to realize various functions of the information processing apparatus 200. Specifically, the CPU 24 collects data from the designated collection target by executing the collection program 211. The CPU 24 analyzes the collected data by executing the analysis program 212. By executing the rule generation program 213, the CPU 24 generates a diagnostic rule based on the analysis result and outputs a diagnostic parameter for applying the diagnostic rule.

The maintenance tool 500 shown in FIG. 2 has a memory 51 for storing various programs and data, an information system network interface 52 for communicating with other devices via the network 702, and an input / output as a user interface, as a hardware configuration. It has a device 53 and a CPU 54 that controls the entire maintenance tool 500. The memory 51, the information network interface 52, and the input / output device 53 are connected to the CPU 54 via the bus 59 and communicate with the CPU 54, respectively.

The memory 51 includes a volatile memory and a non-volatile memory. The memory 51 stores programs for realizing various functions of the maintenance tool 500. Specifically, the memory 51 stores the maintenance program 511. Further, the memory 51 is used as a work memory of the CPU 54.

The maintenance program 511 is a program for realizing various functions of the maintenance tool. The maintenance program 511 enables the maintenance tool 500 to realize a function of transmitting data necessary for the operation of the PLC 100 and the information processing device 200 to the PLC 100 and the information processing device 200. The data transmitted by the maintenance tool 500 to the PLC 100 includes a collection program 111, a user program 112, a diagnostic function block 113, and various setting data required for data collection processing. The data transmitted by the maintenance tool 500 to the information processing apparatus 200 includes various setting data required for data collection processing and various setting data required for analysis processing.

Further, the maintenance program 511 enables the maintenance tool 500 to realize a function of transmitting an instruction to start data collection to the PLC 100 and the information processing apparatus 200. The maintenance program 511 realizes a function of transmitting an instruction to start a rule generation process to the information processing apparatus 200.

The information system network interface 52 includes a network interface circuit, and communicates with the PLC 100 and the information processing device 200 via the network 702 under the control of the CPU 54. The input / output device 53 includes a mouse, a keyboard, and a display. The mouse and keyboard of the input / output device 53 receive the operation input from the user, and output a signal indicating the received operation input to the CPU 54. The display of the input / output device 53 displays an image based on the signal supplied from the CPU 54.

The CPU 54 executes the maintenance program 511 to realize various functions of the maintenance tool 500. Specifically, the CPU 54 transmits various setting data and programs necessary for the operation of the PLC 100 and the information processing device 200 to the PLC 100 and the information processing device 200 according to a user's operation instruction. The CPU 54 transmits an instruction to start the data collection process to the PLC 100 and the information processing apparatus 200 according to the operation instruction of the user. The CPU 54 accepts the designation of the analysis method and executes the analysis process of the collected data according to the operation instruction of the user. The CPU 54 transmits an instruction to start the rule generation process to the information processing apparatus 200 according to the operation instruction of the user.

Subsequently, the functional configuration of each device included in the control system 1 will be described with reference to FIG. Functionally, the PLC 100 includes a collection setting storage unit 110 that stores data collection setting data, a collection unit 120 that collects data from a collection target, a program storage unit 130 that stores control programs and diagnostic programs, and collection. A data storage unit 140 for storing the data, a rule reception unit 150 for receiving diagnostic parameters from the information processing device 200, a first conversion unit 160 for converting a control program, and a second conversion unit 170 for converting a diagnostic program. , An execution unit 180 that executes a control program and a diagnostic program.

The collection setting storage unit 110 stores setting data indicating settings related to the data collection process executed by the collection unit 120. The setting data stored in the collection setting storage unit 110 includes information for specifying a device to be collected, information for specifying data to be collected, and a collection interval for collecting data. The user uses the maintenance tool 500 to store these data in the PLC 100. The function of the collection setting storage unit 110 is realized by the memory 11 shown in FIG.

The collection unit 120 shown in FIG. 1 collects data according to the settings related to the data collection process stored in the collection setting storage unit 110. Specifically, the collection unit 120 collects the designated data from the designated collection target at the designated collection interval, and stores the collected data in the data storage unit 140. In the illustrated example, the collection unit 120 collects data from the FA devices 601 and 602. When the collection unit 120 receives a collection start instruction from the operation reception unit 510 of the maintenance tool 500 described later, the collection unit 120 starts the collection process. The data collected by the collecting unit 120 and the collecting unit 220 of the information processing apparatus 200 described later may be referred to as collected data below. The collected data includes, for example, data acquired by sensors such as a vibration sensor, a temperature sensor, a pressure sensor, and a flow rate sensor provided in the FA device 600. The function of the collection unit 120 is realized by the MPU 14 shown in FIG. 2 executing the collection program 111. The collecting unit 120 is an example of the collecting means of the present invention.

The program storage unit 130 shown in FIG. 1 stores a control program for the PLC 100 to control the FA device 600 and a diagnostic program for the PLC 100 to diagnose the FA device 600. The user program 112 shown in FIG. 2 corresponds to the control program. The diagnostic function block 113 corresponds to the diagnostic program. The function of the program storage unit 130 is realized by the memory 11 shown in FIG. The program storage unit 130 is an example of the program storage means of the present invention.

As described above, the user program 112 incorporates the diagnostic function block 113. Therefore, as shown in FIG. 4, in the program storage unit 130, the function block execution definition 112a is included in the user program 112. When the program is executed, the user program 112 and the diagnostic function block 113 are connected by the internal interface 1131. Therefore, the diagnostic function block 113 is called from the user program 112 and executed. Further, how to call the diagnostic function block 113 from the user program 112 and how to pass the diagnostic result from the diagnostic function block 113 to the user program 112 are defined in advance as the specifications of the PLC 100. The diagnostic function block 113 includes an internal interface 1131 which is a functional unit in which a function is implemented based on this definition. The internal interface 1131 is an example of the internal interface unit of the present invention. Further, the diagnostic function block 113 includes an external interface 1132 that accepts diagnostic parameters. The external interface 1132 will be described later.

The diagnostic function block 113 includes definition information that defines the content of the diagnostic process and definition information regarding diagnostic parameters. In the example shown in FIG. 5, in the diagnostic function block 113, as a diagnostic process, "when the sum of the input value M and the input value N is within the range specified by the upper limit value V1 and the lower limit value V2, it is normal. "Output" high "as a value indicating that" and "when the sum of the input value M and the input value N is outside the range specified by the upper limit value V1 and the lower limit value V2", "Output" low "as a value indicating that it is abnormal" is defined.

The input value M and the input value N are, for example, values indicated by an input signal supplied from the FA device 600. The upper limit value V1 and the lower limit value V2 are supplied from the information processing apparatus 200 to the PLC 100 as diagnostic parameters.

The diagnostic parameters supplied from the information processing apparatus 200 are parameters used for applying the diagnostic rules generated by the information processing apparatus 200 to the diagnostic processing in which the PLC 100 diagnoses the controlled object.

The data storage unit 140 shown in FIG. 1 stores the data collected by the collection unit 120. The function of the data storage unit 140 is realized by the memory 11 shown in FIG. The collecting unit 220 is an example of the collecting means of the present invention.

The rule receiving unit 150 shown in FIG. 1 receives diagnostic parameters from the information processing apparatus 200 and outputs the received diagnostic parameters to the second conversion unit 170. Since the timing at which the information processing apparatus 200 transmits the diagnostic parameters to the PLC 100 and the timing at which the second conversion unit 170 converts the diagnostic program into an executable format are different, the diagnostic parameters received by the rule receiving unit 150 are actually used. It is stored in the memory 11, and the second conversion unit 170 reads out the diagnostic parameters stored in the memory 11. The function of the rule receiving unit 150 is realized by the information system network interface 13 and the MPU 14 shown in FIG. The rule receiving unit 150 is an example of the rule receiving means of the present invention.

The first conversion unit 160 shown in FIG. 1 converts the control program stored in the program storage unit 130 into a format that can be executed by the PLC 100, and outputs the converted control program to the execution unit 180. As described above, the user program 112 shown in FIG. 2, which corresponds to the control program, is described by a ladder diagram. Therefore, the first conversion unit 160 specifically converts the user program 112 into an object code format file, and stores the converted user program 112 in the memory 11. The function of the first conversion unit 160 is realized by the MPU 14 shown in FIG. The first conversion unit 160 is an example of the first conversion means of the present invention.

As shown in FIG. 4, the second conversion unit 170 shown in FIG. 1 has a diagnostic function in which the program storage unit 130 stores the diagnostic parameter P1 received from the information processing device 200 by the rule receiving unit 150 by the external interface 1132. Applies to block 113. How to apply the diagnostic parameter P1 to the diagnostic function block 113 is defined in advance as the specifications of the PLC 100. The external interface 1132 is a functional unit in which a function is implemented based on this definition. The external interface 1132 is an example of the external interface unit of the present invention.

The second conversion unit 170 converts the diagnostic program to which the diagnostic parameters are applied into a format that can be executed by the PLC 100, and outputs the converted diagnostic program to the execution unit 180. As described above, the diagnostic function block 113 shown in FIG. 2, which corresponds to the diagnostic program, is shown in the function block diagram. Therefore, specifically, the second conversion unit 170 converts the diagnostic parameter received from the information processing apparatus 200 into the diagnostic function block 113 into an object code format file, and the converted diagnostic function. The block 113 is stored in the memory 11. The function of the second conversion unit 170 is realized by the MPU 14 shown in FIG. The second conversion unit 170 is an example of the second conversion means of the present invention.

For example, it is assumed that the diagnostic function block 113 defines the diagnostic process as shown in FIG. Here, it is assumed that the information processing apparatus 200 supplies a value indicating the upper limit value V1 and a value indicating the lower limit value V2 as diagnostic parameters. In this case, the second conversion unit 170 substitutes the value indicating the upper limit value V1 and the value indicating the lower limit value V2 into the upper limit value V1 and the lower limit value V2 of the diagnostic function block 113, and substitutes the diagnostic function block 113 for the diagnostic function block 113. Convert to a file in object code format.

The execution unit 180 shown in FIG. 1 combines the converted control program output by the first conversion unit 160 and the diagnostic program output by the second conversion unit 170, and executes the combined program to execute the FA. Diagnose and control equipment 600. Specifically, the execution unit 180 includes the converted user program 112 stored in the memory 11 by the first conversion unit 160 and the converted diagnostic function block 113 stored in the memory 11 by the second conversion unit 170. Execute the combined program. The function of the execution unit 180 is realized by the MPU 14 shown in FIG. The execution unit 180 is an example of the execution means of the present invention.

It is assumed that the user program 112 shown in FIG. 3 incorporates the diagnostic function block 113 as shown in FIG. It is assumed that the information processing apparatus 200 supplies the PLC 100 with "100" as the upper limit value V1 and "20" as the lower limit value V2 as the diagnostic parameter P1 as shown in FIG. An example of each operation of the first conversion unit 160, the second conversion unit 170, and the execution unit 180 in this case will be described.

The first conversion unit 160 converts the user program 112 into a file in the object code format. The second conversion unit 170 substitutes the value "100" indicating the upper limit value V1 into V1 of the diagnostic function block 113, and substitutes the value "20" indicating the lower limit value V2 into V2 of the diagnostic function block 113. After that, the second conversion unit 170 converts the diagnostic function block 113 into an object code format file.

The execution unit 180 combines the user program 112 converted by the first conversion unit 160 and the diagnostic function block 113 converted by the second conversion unit 170, and executes the combined program. When the execution unit determines that the sum of the input value M and the input value N is larger than the value "100" indicating the upper limit value V1 during the execution of the program, "high" is set as a value indicating that it is normal. Output. Further, when the execution unit 180 determines that the sum of the input value M and the input value N is less than the value "20" indicating the lower limit value V2, the execution unit 180 outputs "low" as a value indicating an abnormality. As a result, the "instruction 004" shown in FIG. 3 is not executed. In this way, the execution unit 180 diagnoses that the sum of the input value M and the input value N is normal if it is within the range specified by the information processing apparatus 200, and is abnormal if it is outside the specified range. Diagnose that there is.

As shown in FIG. 1, the information processing apparatus 200 functionally includes a collection setting storage unit 210 that stores data collection setting data, a collection unit 220 that collects data from a collection target, and data analysis setting data. An analysis setting storage unit 230 that stores the data, an analysis unit 240 that analyzes the collected data, a diagnostic rule generation unit 250 that generates a diagnostic rule based on the analysis result, and a rule supply unit 260 that supplies diagnostic parameters to the PLC 100. including.

The collection setting storage unit 210 stores setting data indicating settings related to the data collection process executed by the collection unit 220. The setting data stored in the collection setting storage unit 210 includes information for specifying a device to be collected, information for specifying data to be collected, and a collection interval for collecting data. The user uses the maintenance tool 500 to store these data in the information processing apparatus 200. The function of the collection setting storage unit 210 is realized by the memory 21 shown in FIG.

The collection unit 220 shown in FIG. 1 collects data according to the settings related to the data collection process stored in the collection setting storage unit 210. Specifically, the collection unit 220 collects the designated data from the designated collection target at the designated collection interval, and outputs the collected data to the analysis unit 240. When the collection unit 220 receives a collection start instruction from the user via the maintenance tool 500, the collection unit 220 starts the collection process.

In the illustrated example, the collection unit 220 collects data directly from the FA device 603. The collecting unit 220 acquires the data stored in the data storage unit 140 of the PLC 100. In other words, the collecting unit 220 collects data from the FA devices 601 and 602 via the PLC 100. The function of the collection unit 220 is realized by the CPU 24 shown in FIG. 2 executing the collection program 211.

The analysis setting storage unit 230 stores setting data indicating settings related to the analysis process executed by the analysis unit 240. The analysis setting storage unit 230 stores various parameters corresponding to each analysis method executed by the analysis unit 240 as setting data. The analysis method used by the analysis unit 240 includes multiple regression analysis, MT (Mahalanobis Taguchi) method, decision tree and the like. For example, the analysis setting storage unit 230 stores an objective variable, an explanatory variable, an initial value of a partial regression coefficient, and the like as parameters for multiple regression analysis. The analysis setting storage unit 230 stores data in the unit space as a parameter of the MT method. The analysis setting storage unit 230 stores the data to be branched and its threshold value as parameters of the decision tree. The user uses the maintenance tool 500 to store data indicating these parameters in the analysis setting storage unit 230. The function of the analysis setting storage unit 230 is realized by the memory 21 shown in FIG.

Further, the analysis setting storage unit 230 stores the minimum number of data that needs to be collected. This number of data is a start condition for the analysis unit 240 to start the analysis process.

When the analysis unit 240 receives an instruction to start the collection process from the operation reception unit 510 of the maintenance tool 500 described later, the analysis unit 240 causes the collection unit 220 to start the collection process. When the analysis process can be started, that is, when the start condition is satisfied, the analysis unit 240 notifies the maintenance tool 500, for example, to that effect. In response to this, the operation reception unit 510 of the maintenance tool 500 displays the analysis method selection screen on the display of the input / output device 53. When the user selects a desired analysis method, the operation reception unit 510 transmits a diagnosis rule generation start instruction to the information processing device 200 together with information identifying the selected analysis method.

Therefore, the analysis unit 240 starts the analysis process by the analysis method selected by the user. Specifically, the analysis unit 240 analyzes the collected data by the selected analysis method using the parameters stored in the analysis setting storage unit 230 for the analysis method selected by the user. The analysis unit 240 outputs the analysis result to the diagnostic rule generation unit 250.

For example, when the user specifies to use multiple regression analysis as the analysis method, the analysis unit 240 sets the value specified by the user in the collected data as the objective variable and explains the value specified by the user in the collected data. Perform multiple regression analysis as a variable. The analysis unit 240 outputs the estimated regression equation, the multiple correlation coefficient, the coefficient of determination, and the like as the analysis result to the diagnostic rule generation unit 250. The function of the analysis unit 240 is realized by the CPU 24 shown in FIG. 2 executing the analysis program 212. The analysis unit 240 is an example of the analysis means of the present invention.

The diagnostic rule generation unit 250 generates a diagnostic rule from the analysis result output by the analysis unit 240, and outputs the diagnostic parameters used for applying the diagnostic rule to the rule supply unit 260. Diagnostic rules determine, for example, the permissible range of values for an expression. For example, the diagnostic rule generation unit 250 can obtain a threshold value for determining an outlier of the values output by the FA devices 601 to 603 from the estimated regression model indicated by the regression equation output by the analysis unit 240. The diagnostic rule generation unit 250 determines the upper limit value and the lower limit value of each of the values output by the FA devices 601 to 603 as the threshold value for determining the outlier. The function of the diagnostic rule generation unit 250 is realized by the CPU 24 shown in FIG. 2 executing the rule generation program 213. The diagnostic rule generation unit 250 is an example of the diagnostic rule generation means of the present invention.

The rule supply unit 260 shown in FIG. 1 transmits the diagnostic parameters output by the diagnostic rule generation unit 250 to the rule receiving unit 150 of the PLC 100. The function of the rule supply unit 260 is realized by the information system network interface 23 and the CPU 24 shown in FIG. The rule supply unit 260 is an example of the rule supply means of the present invention.

As shown in FIG. 1, the maintenance tool 500 functionally includes an operation reception unit 510. The operation reception unit 510 transmits a signal indicating the operation received from the user and the data input by the user to the PLC 100 and the information processing apparatus 200.

Specifically, the operation reception unit 510 causes the PLC 100 to display the setting data indicating the settings related to the data collection process, the control program and the diagnostic program stored in the program storage unit 130, and the collection program 211 according to the operation instruction of the user. Send. The operation reception unit 510 transmits the setting data indicating the setting related to the data collection process and the setting data indicating the setting related to the analysis process to the information processing apparatus 200 according to the operation instruction of the user.

Further, the operation reception unit 510 transmits a signal indicating a data collection start instruction received from the user to the PLC 100 and the information processing device 200. The operation reception unit 510 transmits the diagnosis rule generation start instruction received from the user to the information processing apparatus 200 together with the information indicating the analysis method selected by the user. The function of the operation reception unit 510 is realized by the CPU 54 shown in FIG.

Subsequently, a diagnostic rule generation process in which the information processing apparatus 200 generates a diagnostic rule will be described. The information processing apparatus 200 needs to generate a diagnostic rule before the PLC 100 starts executing the control program. The collection unit 220, the analysis unit 240, the diagnostic rule generation unit 250, and the collection unit 120 of the PLC 100 shown in FIG. 1 cooperate with each other to execute the following processing.

It is assumed that the user has instructed the PLC 100 to start the collection process by using the maintenance tool 500. Therefore, the collection unit 120 of the PLC 100 collects data from the FA devices 601 and 602 at the designated collection interval, and stores the collected data in the data storage unit 140. Further, it is assumed that the user has instructed the information processing apparatus 200 to start the collection process by using the maintenance tool 500.

As shown in FIG. 7, the collection unit 220 determines whether or not it is the timing to collect data based on the data indicating the collection interval stored by the collection setting storage unit 210 (step S11). When the collection unit 220 determines that it is time to collect the data (step S11; Yes), the collection unit 220 collects the specified data from the designated collection target (step S12), and outputs the collected data to the analysis unit 240. .. Specifically, the collecting unit 220 reads out the data stored in the data storage unit 140 of the PLC 100. Further, the collecting unit 220 reads data from the designated location in the memory of the FA device 603.

The analysis unit 240 determines whether or not the analysis process can be started based on the data set in the analysis setting storage unit 230 (step S13). Specifically, it is determined whether or not the number of collected data reaches the number of data for which the minimum number of collected data stored in the analysis setting storage unit 230 needs to be collected. When the analysis unit 240 determines that the analysis process can be started (step S13; Yes), the analysis unit 240 accepts the designation of the analysis method from the user (step S14). For example, a list of analysis methods stored in the analysis setting storage unit 230 is displayed on the display of the input / output device 53. It is assumed that the user selects a desired analysis method using the keyboard, mouse, or the like of the input / output device 53. The analysis unit 240 executes the analysis process of the collected data for the analysis method selected by the user by using the parameters for the analysis process stored in the analysis setting storage unit 230 (step S15).

When the analysis is completed, the analysis unit 240 presents the analysis result to the user (step S16). The analysis unit 240 transmits the screen data showing the analysis result to the maintenance tool 500 shown in FIG. In response to this, the CPU 54 of the maintenance tool 500 displays the received screen data on the display of the input / output device 53.

As shown in FIG. 7, the analysis unit 240 determines whether or not it is possible to generate a diagnostic rule from the analysis result (step S17). When the analysis unit 240 receives an instruction to generate a diagnostic rule from the maintenance tool 500, the analysis unit 240 determines that the diagnostic rule can be generated. When the analysis unit 240 determines that the diagnostic rule can be generated (step S17; Yes), the analysis unit 240 outputs the analysis result to the diagnostic rule generation unit 250.

On the other hand, when the analysis unit 240 determines that the diagnostic rule cannot be generated from the analysis result (step S17; No), the analysis unit 240 executes the process of step S14 again. For example, if the user's instruction received through the maintenance tool 500 is not an instruction to generate a diagnostic rule but an instruction to execute the analysis again, the analysis unit 240 executes the process of step S14 again. ..

In step S18, the diagnostic rule generation unit 250 generates a diagnostic rule (step S18). Here, it is assumed that the control target is the FA device 601. For example, the diagnostic rule generation unit 250 obtains a range expected as a value that can be taken as the sum of the input value M and the input value N in the normal state from the analysis result of the data collected from the FA device 601. The diagnostic rule generation unit 250 determines that the FA device 601 is diagnosed as normal when the sum of the input value M and the input value N is within the obtained range. When the sum of the input value M and the input value N is out of the range, the diagnosis rule generation unit 250 determines that the FA device 601 is diagnosed as having an abnormality. The diagnostic rule generation unit 250 obtains a value indicating an upper limit value and a lower limit value of the range, and outputs the obtained value to the rule supply unit 260 as a diagnostic parameter.

The rule supply unit 260 transmits the diagnostic parameters output by the diagnostic rule generation unit 250 to the PLC 100 (step S19). The above is the process related to the generation of diagnostic rules.

By executing the above-mentioned diagnostic rule generation process, diagnostic parameters are supplied to the PLC 100. In order to diagnose the FA device 600 by using the diagnostic parameters supplied from the information processing apparatus 200, the PLC 100 needs to perform the execution preparation process described below prior to the execution of the control program.

The execution preparation process is included in the initialization process executed by the PLC 100 after the power is turned on to the PLC 100. Therefore, when the power is turned on to the PLC 100 or the PLC 100 is restarted, the first conversion unit 160 and the second conversion unit 170 shown in FIG. 1 execute the execution preparation process. It is assumed that the control program and the diagnostic program are stored in the program storage unit 130 in advance. It is assumed that the rule receiving unit 150 has received the diagnostic parameters from the information processing device 200.

As shown in FIG. 8, the second conversion unit 170 reads the diagnostic program from the program storage unit 130 (step S21). The second conversion unit 170 sets the diagnostic parameters stored in the memory 11 in the diagnostic program, converts the diagnostic program into a format that can be executed by the PLC 100 (step S22), and transfers the converted diagnostic program to the execution unit 180. Output.

The first conversion unit 160 reads a control program from the program storage unit 130 shown in FIG. 1 (step S23). The first conversion unit 160 converts the control program into a format that can be executed by the PLC 100 (step S24), and outputs the converted control program to the execution unit 180. The execution unit 180 combines the control program converted into the executable format and the diagnostic program converted into the executable format, and stores the combined program in the memory 11. Specifically, the execution unit 180 combines the file in which the user program 112 shown in FIG. 2 is converted into the object code format and the file in which the diagnostic function block 113 is converted into the object code format. The above is the process related to execution preparation.

After that, when the operation mode is entered by the user's switch operation, the execution unit 180 executes the control program in which the diagnostic program is incorporated every scan time. Specifically, the PLC 100 periodically acquires an input signal supplied from the FA device 600, and uses the acquired input signal to execute a program instruction. As described above, since the control program incorporates diagnostic logic, the PLC 100 diagnoses and diagnoses the FA device 600 according to the diagnostic rules supplied from the information processing device 200 during the execution of the control program. The FA device 600 can be controlled according to the result.

As described above, in the control system 1 according to the embodiment, the information processing apparatus 200 generates a diagnostic rule and supplies the diagnostic parameter used for applying the diagnostic rule to the PLC 100. The PLC 100 executes a control program incorporating a diagnostic program in which parameters supplied from the information processing apparatus 200 are set. By providing such a configuration, the control system 1 can diagnose the device to be controlled and immediately control the device to be controlled based on the diagnosis result. Further, since the information processing apparatus 200 generates a diagnostic rule from the result of analyzing the data collected from the controlled object, the PLC 100 can appropriately diagnose the controlled object by using the diagnostic rule suitable for the controlled object. ..

In the embodiment, since the diagnostic process is executed using the diagnostic functional block 113, there are the following advantages. If there is no change in the internal interface 1131 for connecting the user program 112 and the diagnostic function block 113, simply change the function block execution definition 112a in the user program 112 and change the diagnostic function block 113 to be called. , The diagnostic function can be changed.

As described above, the diagnostic function block 113 is created by the manufacturer of the PLC 100. For example, when the diagnostic function block 113 is updated, the user of the PLC 100 may save the new diagnostic function block 113 in the PLC 100 and cause the PL1C 100 to execute the execution preparation process again. Further, even when the user wants to adopt an algorithm of the diagnostic processing different from the current diagnostic process, the new diagnostic function block 113 may be saved in the PLC 100 and the PL1C 100 may execute the execution preparation process again. The user can apply the new diagnostic function block 113 to the user program 112 without changing the function block execution definition 112a in the user program 112. Therefore, the user does not need to make major modifications to the user program 112.

The PLC 100 diagnoses the FA devices 601 to 603 by executing a diagnostic function block in which diagnostic parameters supplied from the information processing apparatus 200 are set. When the diagnostic rule is changed, the information processing apparatus 200 may supply the diagnostic parameter generated from the new diagnostic rule to the PLC 100. When the PLC 100 executes the pre-execution process again, new diagnostic parameters can be set in the diagnostic function block. The user does not need to modify the control program and the diagnostic program of the PLC 100. In this way, even if the information processing apparatus 200 changes the diagnostic rule, the PLC 100 can apply the changed diagnostic rule by a simple method.

Further, data analysis and generation of diagnostic rules are processes with a high processing load, but since these processes are executed by the information processing apparatus 200 instead of the PLC 100, the FA device which is the original process of the PLC 100 It does not affect the control processing of 601 to 603.

The analysis unit 240 explained an example in which the analysis result is output to the diagnostic rule generation unit 250 as it is, but the analysis unit 240 tests the significance of the regression equation estimated from the multiple correlation coefficient and the coefficient of determination after the analysis. You may. The analysis unit 240 may output the analysis result to the diagnostic rule generation unit 250 when the regression equation has significance.

When the rule supply unit 260 transmits a diagnostic parameter to the PLC 100, the rule supply unit 260 may notify the user to that effect. For example, the rule supply unit 260 sends an e-mail notifying that the diagnostic parameter has been sent to the PLC 100 to the maintenance tool 500. Upon receiving the notification that the diagnostic parameters have been transmitted to the PLC 100, the user can restart the PLC 100 and apply the latest diagnostic parameters to the diagnostic function block 113.

Further, since the information processing apparatus 200 generates a diagnostic rule from the analysis result of the data collected from the FA device 600, the diagnostic rule cannot be generated until some data is collected from the FA device 600. The PLC 100 may store the default diagnostic parameters in the memory 11. The PLC 100 can apply the default diagnostic parameters to the diagnostic function block 113 until it receives the initial diagnostic parameters from the information processing apparatus 200. Further, the PLC 100 may have a default diagnostic parameter in case the diagnostic parameter received from the information processing apparatus 200 is damaged for some reason. In this case, when the diagnostic parameters received from the information processing apparatus 200 are damaged, the PLC 100 may apply the default diagnostic parameters to the diagnostic function block 113.

In the embodiment, an example in which the information processing device 200 collects data directly from the FA device 603 has been described, but the present invention is not limited to this. The information processing device 200 may collect data from all FA devices 600 via the PLC 100. Alternatively, the information processing apparatus 200 may collect data directly from all FA devices 600 without going through the PLC 100.

In the embodiment, the information processing device 200 analyzes the data collected from one PLC 100 to generate a diagnostic rule, but the information processing device 200 is in the same factory or in a different factory. Data may be collected from a plurality of PLCs, and a diagnostic rule may be generated from the analysis result of the collected data.

The information processing device 200 generates a diagnostic rule from the result of analyzing the data collected from the FA device 600, but the information processing device 200 is not limited to this. The information processing apparatus 200 may analyze the data accumulated in advance and generate a diagnostic rule from the analysis result. The data accumulated in advance may be data acquired from the FA device 600, or may be data acquired from a machine device of the same type as the FA device 600 but different from the FA device 600. Good.

(Modification example)
In the embodiment, an expression is set in the function block, and in order to determine whether or not the value n is within the set range by this expression, the information processing apparatus 200 uses the upper limit value and the upper limit value as diagnostic parameters. An example of supplying the lower limit value to the PLC 100 has been described, but the present invention is not limited to this. The information processing apparatus 200 may supply an expression as a diagnostic parameter instead of a value.

For example, as shown in FIG. 9A, in the diagnostic function block 113A, as a diagnostic process, "a value indicating that the equation 1 is normal when it is within the range specified by the upper limit value V1 and the lower limit value V2". "Output" high "as", and "when Equation 1 is outside the range specified by the upper limit value V1 and the lower limit value V2," low "is output as a value indicating that it is abnormal. ", And is defined.

In this case, the information processing apparatus 200 supplies the equation 1, the upper limit value V1, and the lower limit value V2 as the diagnostic parameter P2 as shown in FIG. 9B.

Further, for example, as shown in FIG. 10A, as diagnostic processing, "output" high "when equation 2 is satisfied" and "when equation 2 is not satisfied" are displayed in the diagnostic function block 113B. It is assumed that "outputting" low "" is defined.

In this case, the information processing apparatus 200 supplies Equation 2 as the diagnostic parameter P3 as shown in FIG. 10B.

In the above embodiment, the FA device 600 is the diagnosis target and the control target of the PLC 100, and the diagnosis target and the control target are the same, but the present invention is not limited to this. The device to be diagnosed and the device to be controlled may be different. For example, the PLC 100 may stop the processing machine to be controlled when it diagnoses the transport device and determines that a defect has occurred in the transport device. Alternatively, a control target may be included as a part of the diagnosis target.

In the embodiment, an example has been described in which the diagnostic function block 113 outputs a value indicating normality and two values indicating abnormality as a result of diagnostic processing, but the present invention is not limited to this. .. For example, it may be defined in advance that three or more values are output as the diagnosis result. In this case, the diagnostic function block 113 outputs any of the defined values as the diagnostic result.

In the embodiment, an example has been described in which the information processing apparatus 200 generates a diagnostic rule based on the analysis result and outputs a diagnostic parameter for applying the diagnostic rule, but the present invention is not limited to this. The information processing device 200 does not have to generate a diagnostic rule. For example, the information processing apparatus 200 may output diagnostic parameters based on a diagnostic rule given in advance and an analysis result.

In the embodiment, an example of using an industrial PC as the information processing device 200 has been described, but the present invention is not limited to this. As the information processing device 200, a personal computer may be used, or a server on the cloud may be used.

In the embodiment, an example of using a personal computer in which a dedicated application is installed as the maintenance tool 500 has been described, but the present invention is not limited to this. For example, a computer that functions as an information processing device 200 may further function as a maintenance tool 500. Alternatively, the server on the cloud may function as the maintenance tool 500.

As the recording medium for recording the above program, a computer-readable recording medium including a magnetic disk, an optical disk, a magneto-optical disk, a flash memory, a semiconductor memory, and a magnetic tape can be used.

The present invention allows for various embodiments and modifications without departing from the broad spirit and scope. Moreover, the above-described embodiment is for explaining the present invention, and does not limit the scope of the present invention. That is, the scope of the present invention is indicated not by the embodiment but by the claims. Then, various modifications made within the scope of the claims and the equivalent meaning of the invention are considered to be within the scope of the present invention.

M, N input values, P1, P2, P3 diagnostic parameters, V1 upper limit, V2 lower limit, 1 control system, 11,21,51 memory, 12,22 field bus interface, 13,23,52 information system network interface, 14 MPU, 19, 29, 59 bus, 24, 54 CPU, 53 input / output device, 100 programmable logic controller (PLC), 110, 210 collection setting storage unit, 111,211 collection program, 112 user program, 112a function block execution Definition, 113, 113A, 113B Diagnostic function block, 120, 220 Collection unit, 130 Program storage unit, 140 Data storage unit, 150 Rule reception unit, 160 1st conversion unit, 170 2nd conversion unit, 180 Execution unit, 200 Information processing device, 212 analysis program, 213 rule generation program, 230 analysis setting storage unit, 240 analysis unit, 250 diagnostic rule generation unit, 260 rule supply unit, 500 maintenance tool, 510 operation reception unit, 511 maintenance program, 601 to 603 (600) FA equipment, 701,702 network, 1131 internal interface, 1132 external interface

To achieve the above object, a control system according to the present invention, an information processing apparatus for supplying diagnostic parameters used in the application of the diagnostic rules for diagnosing the diagnostic object, and a programmable logic controller for diagnostics and control including. Lulu Lumpur supply means comprises an information processing apparatus supplies the diagnostic parameters to the programmable logic controller. Program storage means comprises a programmable logic controller includes a diagnostic function block that to realize the function of diagnosing the diagnostic object, stores to that control program realizing the function of controlling the control target. The storage means for storing the default parameters provided in the programmable logic controller stores the default parameters which are the initial setting values of the diagnostic parameters. The execution means provided in the programmable logic controller diagnoses the diagnosis target by executing a control program including a diagnosis function block in which diagnostic parameters are set, and controls the control target according to the diagnosis result. The execution means executes a control program including a diagnostic function block in which default parameters are set until the diagnostic parameters are supplied from the information processing device, and when the diagnostic parameters are supplied from the information processing device, the supplied diagnostic parameters are set. Execute the control program including the default diagnostic function block.

In order to achieve the above object, the control system according to the present invention includes an information processing device that supplies diagnostic parameters used for applying diagnostic rules for diagnosing a diagnostic object, and a programmable logic controller that performs diagnosis and control. Including. The rule supply means included in the information processing device supplies diagnostic parameters to the programmable logic controller. Program storage means comprises a programmable logic controller includes a control program for realizing the function of controlling the control target, the external interface unit that receives an internal interface unit and diagnostic parameters for coupling to a control program, to diagnose the diagnostic object Store the diagnostic function block that realizes the function . The storage means for storing the default parameters provided in the programmable logic controller stores the default parameters which are the initial setting values of the diagnostic parameters. The execution means provided in the programmable logic controller diagnoses the diagnostic target by executing a control program in which diagnostic function blocks in which diagnostic parameters are set by the external interface section are combined by the internal interface section , and the control target is set according to the diagnosis result. Control. The execution means executes a control program including a diagnostic function block in which default parameters are set until the diagnostic parameters are supplied from the information processing device, and when the diagnostic parameters are supplied from the information processing device, the supplied diagnostic parameters are set. Execute the control program including the default diagnostic function block.

Claims (10)

A control system that includes an information processing device that supplies diagnostic parameters used to apply diagnostic rules for diagnosing a diagnostic target, and a programmable logic controller that diagnoses and controls the diagnostic target.
The information processing device
A rule supply means for supplying the diagnostic parameters to the programmable logic controller,
With
The programmable logic controller
A program including a diagnostic function block for realizing a diagnostic processing function, and a program storage means for storing a control program for executing a process for controlling a controlled object.
By executing the control program including the diagnostic function block in which the diagnostic parameters are set, the diagnostic target is diagnosed, and the control target is controlled according to the diagnosis result.
Control system with. The programmable logic controller
A first conversion means for converting the diagnostic function block in which the diagnostic parameters are set into a format that can be executed by the programmable logic controller, and
A second conversion means that converts the control program into a format that can be executed by the programmable logic controller, and
With
The execution means combines the diagnostic function block converted by the first conversion means with the control program converted by the second conversion means, and executes the combined program to diagnose the diagnosis target. , The control target is controlled according to the diagnosis result.
The control system according to claim 1. The control program is described by a ladder diagram, and the diagnostic function block is a componentized program described by a function block diagram.
The control system according to claim 1 or 2. The information processing device
A collection means for collecting data from the diagnosis target and
An analysis means that analyzes the data collected by the collection means and outputs the analysis result,
A diagnostic rule generating means that generates a diagnostic rule for diagnosing the diagnostic target and outputs the diagnostic parameter used for applying the diagnostic rule.
To prepare
The control system according to any one of claims 1 to 3. The collecting means included in the information processing device collects data from the diagnosis target via the programmable logic controller, or collects data directly from the diagnosis target.
The control system according to claim 4. The control target includes the diagnosis target.
The control system according to any one of claims 1 to 5. The control target does not include the diagnosis target.
The control system according to any one of claims 1 to 5. A program including a diagnostic function block for realizing a diagnostic processing function, and a program storage means for storing a control program for executing the control processing,
A rule receiving means for receiving diagnostic parameters used to apply diagnostic rules for diagnosing the diagnostic target, and
An execution means for diagnosing the diagnostic target and controlling the control target according to the diagnosis result by executing the control program incorporating the diagnostic function block in which the diagnostic parameters are set.
Programmable logic controller with. A step in which the information processing device supplies the programmable logic controller with diagnostic parameters used to apply diagnostic rules for diagnosing the diagnostic target of the programmable logic controller.
A step in which the programmable logic controller sets the diagnostic parameters in a diagnostic function block for realizing a diagnostic processing function.
A step in which the programmable logic controller combines the diagnostic parameters with a control program for executing a process of controlling a controlled object.
A step in which the programmable logic controller diagnoses the diagnosis target by executing the control program to which the diagnosis function block is combined.
A step in which the programmable logic controller controls the controlled object by executing the control program.
How to include. A control program for executing the process of controlling the controlled object,
A functional block incorporated in the control program, which is a diagnostic function block in which diagnostic parameters used for applying a diagnostic rule for diagnosing a diagnostic target are set and realizes a diagnostic processing function.
Including
The diagnostic function block includes an internal interface unit for the diagnostic function block to connect to the control program, and an external interface unit for receiving the diagnostic parameters.
On the computer
Have the diagnosis target diagnosed
The control target is controlled according to the diagnosis result.
program.

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