WO2020166004A1

WO2020166004A1 - Control system, programmable logic controller, method, and program

Info

Publication number: WO2020166004A1
Application number: PCT/JP2019/005342
Authority: WO
Inventors: 督那須; 大介渡辺
Original assignee: 三菱電機株式会社
Priority date: 2019-02-14
Filing date: 2019-02-14
Publication date: 2020-08-20
Also published as: CN113424115A; JPWO2020166004A1

Abstract

A control system (1) includes: an information processing device (200) that supplies diagnostic parameters used for the application of diagnostic rules for diagnosing FA devices (601, 602, 603); and a PLC (100) for diagnosing and controlling the FA devices (601, 602, 603). A rule supply unit (260) for the information processing device (200) supplies diagnostic parameters to the programmable logic controller. A program storage unit (130) in the PLC (100) stores control programs that: include diagnostic function blocks for achieving diagnostic processing functions; and are for executing processing that controls the FA devices (601, 602, 603). An execution unit (180) in the PLC (100) diagnoses the FA devices (601, 602, 603) and controls the FA devices (601, 602, 603) according to the diagnostic results, by executing a control program that includes a diagnostic function block having diagnostic parameters set.

Description

Control system, programmable logic controller, method, and program

The present invention relates to a control system, a programmable logic controller, a method, and a program.

In factories, plants, etc. that are production sites, programmable logic controllers and higher-level systems that manage the programmable logic controllers work together for the purpose of preventive maintenance of equipment, improvement of manufacturing quality, etc. The machine used in the process may be diagnosed.

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.

Japanese Patent Laid-Open No. 2002-062933

In the configuration described in Patent Document 1, after the field device outputs an alert according to the diagnosis result, for example, an operator needs to take necessary measures for the device. In this case, in many cases, after the field device outputs an alert, the operator cannot immediately take action on the device. Therefore, 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 thereof is to allow a programmable logic controller to immediately control a device to be controlled after diagnosing the device to be controlled.

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

In the control system according to the present invention, the information processing device supplies the programmable logic controller with a diagnostic parameter used for applying a diagnostic rule for diagnosing a diagnostic target. The programmable logic controller executes a control program including a diagnostic function block in which diagnostic parameters are set to diagnose a diagnostic target and control the controlled target according to the diagnostic 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 constitutions of each apparatus contained 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 2nd conversion part of the programmable logic controller which concerns on embodiment. The figure which shows the example of the functional block for a diagnosis which concerns on embodiment. The figure which shows the example of the diagnostic parameter which concerns on embodiment. Flowchart of diagnostic rule generation processing according to the embodiment Flowchart of execution preparation processing according to the embodiment The figure which shows the example of the functional block for a diagnosis which concerns on a modification. The figure which shows the example of the diagnostic parameter which concerns on a modification. The figure which shows the example of the other functional block for a diagnosis which concerns on a modification. The figure which shows the example of the other diagnostic parameter which concerns on a modification.

Hereinafter, a control system according to an 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 the FA devices 601 to 603, an information processing device 200 that generates a diagnostic rule, and a maintenance tool 500 for a user to operate the programmable logic controller. Including.

The programmable logic controller 100 (hereinafter referred to as the PLC 100) is a control device that controls the

FA devices

601, 602 and 603 in the production system.

FA devices

601, 602 and 603 are mechanical devices that operate in a production line. The PLC 100 controls the

FA devices

601, 602 and 603 by executing the control program. Specifically, the PLC 100 executes each instruction of the control program for each scan time that is a set cycle, thereby performing an operation using the values indicated by the input signals supplied from the

FA devices

601, 602, and 603. Then, an 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 rule supplied from the information processing device 200 during the execution of the control program, and controls the FA device 600 according to the diagnostic result. .. The FA device 600 is a diagnosis target of the PLC 100 and is a control target.

The information processing device 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 that is a parameter used for applying the generated diagnostic rule. .. The information processing device 200 performs analysis and generation of diagnostic rules before the PLC 100 starts executing the control program. As the information processing apparatus 200, for example, an industrial PC (Industrial Personal Computer: IPC) is used.

In the diagnostic process executed by the PLC 100, for example, if the value indicating the calculation result is within the specified range, it is diagnosed as normal, and if it is out of the specified range, it is abnormal. It is a thing. When the PLC 100 performs such a diagnosis process, the information processing apparatus 200 obtains the upper limit value and the lower limit value that define the specified range from the analysis result, and supplies the obtained condition value and the lower limit value to the PLC 100 as a diagnostic parameter. To do.

The maintenance tool 500 is a tool for the user to operate the PLC 100. The user uses the maintenance tool 500 to create a program necessary for controlling the FA device 600, 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 apparatus 200 to operate in the PLC 100 and the information processing apparatus 200, respectively. As the maintenance tool 500, for example, a personal computer installed with a dedicated application installed in the same factory as the FA device 600 is used. Here, the user is, for example, an administrator of the PLC 100.

As shown in FIG. 2, the PLC 100 has, as a hardware configuration, a memory 11 that stores various programs and data, a fieldbus interface 12 that communicates with other devices via a network 701, and another via a network 702. It has an information network interface 13 for communicating with the above device and an MPU (Micro Processing Unit) 14 for controlling 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 communicate with the MPU 14, respectively.

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 a collection program 111, a user program 112, and a diagnostic function block 113. Further, the memory 11 is used as a work memory for the MPU 14.

The collection program 111 is a program for causing the PLC 100 to realize a function of collecting data from a designated target.

The user program 112 is a program for causing the PLC 100 to realize a function of controlling a control target. The user program 112 is described by a ladder diagram. The user program 112 is a program created by the user.

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

In the embodiment, the user creates the 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 apparatus 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 network interface 13 includes a network interface circuit, and communicates with the information processing device 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 the standards such as 10BASE-T and 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 executes the collection program 111 to collect data from the designated collection target. The MPU 14 executes the user program 112 in which the diagnostic function block 113 is incorporated to control and diagnose the FA device 600.

The information processing device 200 has, as a hardware configuration, a memory 21 that stores various programs and data, a fieldbus interface 22 that communicates with another device via a network 701, and a communication with 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 apparatus 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 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 device 200. Specifically, the memory 21 stores a collection program 211, an analysis program 212, and a rule generation program 213. Further, the memory 21 is used as a work memory for the CPU 24.

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

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 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 device 200. Specifically, the CPU 24 executes the collection program 211 to collect data from the designated collection target. The CPU 24 analyzes the collected data by executing the analysis program 212. The CPU 24 executes the rule generation program 213 to generate 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, as a hardware configuration, a memory 51 that stores various programs and data, an information network interface 52 that communicates with other devices via a network 702, and an input/output that is a user interface. 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 for the CPU 54.

The maintenance program 511 is a program for realizing various functions of the maintenance tool. The maintenance program 511 causes the maintenance tool 500 to realize a function of transmitting data required for the operations of the PLC 100 and the information processing apparatus 200 to the PLC 100 and the information processing apparatus 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 necessary for data collection processing. The data transmitted by the maintenance tool 500 to the information processing apparatus 200 includes various setting data required for the data collection process and various setting data required for the analysis process.

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

The information 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 an 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 and realizes 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 the user's operation instruction. The CPU 54 transmits a data collection processing start instruction to the PLC 100 and the information processing apparatus 200 in accordance with a user's operation instruction. The CPU 54 receives the designation of the analysis method according to the operation instruction of the user, and executes the analysis processing of the collected data. The CPU 54 transmits a rule generation processing start instruction to the information processing apparatus 200 in accordance with a user operation instruction.

Next, the functional configuration of each device included in the control system 1 will be described with reference to FIG. The PLC 100 functionally includes a collection setting storage unit 110 that stores setting data for data collection, a collection unit 120 that collects data from a collection target, a program storage unit 130 that stores a control program and a diagnostic program, and a collection unit A data storage unit 140 that stores the selected data, a rule reception unit 150 that receives a diagnostic parameter from the information processing device 200, a first conversion unit 160 that converts a control program, and a second conversion unit 170 that converts a diagnostic program. , And 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 processing executed by the collection unit 120. The setting data stored in the collection setting storage unit 110 includes information specifying a device to be collected, information specifying the data to be collected, and a collection interval for collecting the data. The user stores these data in the PLC 100 using the maintenance tool 500. 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 processing 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, which will be described later, the collection unit 120 starts the collection process. The data collected by the collection unit 120 and the collection unit 220 of the information processing apparatus 200 described below may be referred to as collection data hereinafter. The collected data includes, for example, data acquired by sensors such as a vibration sensor, a temperature sensor, a pressure sensor, and a flow 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 a collecting unit 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 a 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 functional block 113 for diagnosis is incorporated in the user program 112. 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 will be 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 receives diagnostic parameters. The external interface 1132 will be described later.

The diagnostic function block 113 includes definition information defining the content of the diagnostic process and definition information regarding diagnostic parameters. In the example shown in FIG. 5, the diagnostic function block 113 indicates that if 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, the diagnostic process is performed normally. Output "high" as a value indicating that ", and "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 values indicated by the input signal supplied from the FA device 600, for example. 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 parameter supplied from the information processing device 200 is a parameter used for applying the diagnostic rule generated by the information processing device 200 to the diagnostic process in which the PLC 100 diagnoses the control target.

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 a diagnostic parameter from the information processing device 200 and outputs the received diagnostic parameter to the second converting unit 170. Since the timing at which the information processing device 200 transmits the diagnostic parameter 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 parameter received by the rule reception unit 150 is actually The second conversion unit 170 stores the diagnostic parameters in the memory 11, and reads 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 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 executable 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 corresponding to the control program is described in the ladder diagram. Therefore, the first conversion unit 160 specifically converts the user program 112 into a file in the object code format 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 1st conversion part 160 is an example of the 1st conversion means of the present invention.

As shown in FIG. 4, the second conversion unit 170 shown in FIG. 1 stores the diagnostic parameter P1 received by the rule receiving unit 150 from the information processing apparatus 200 in the program storage unit 130 via 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 parameter is applied into a format executable 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 corresponding to the diagnostic program is described in the function block diagram. Therefore, the second conversion unit 170 specifically converts the diagnostic function block 113 into which the diagnostic parameters received from the information processing apparatus 200 are substituted into a file in the object code format, 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 2nd conversion part 170 is an example of the 2nd conversion means of the present invention.

For example, it is assumed that the diagnostic function block 113 defines a diagnostic process as shown in FIG. Here, it is assumed that a value indicating the upper limit value V1 and a value indicating the lower limit value V2 are supplied from the information processing apparatus 200 as the 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 sets the diagnostic function block 113. Convert to a file in object code format.

The execution unit 180 illustrated 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 FA Diagnose and control the device 600. Specifically, the execution unit 180 stores 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.

Assume that the user program 112 shown in FIG. 3 incorporates a 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 an object code format file. The second conversion unit 170 substitutes the value “100” indicating the upper limit value V1 into V1 of the diagnosis function block 113, and substitutes the value “20” indicating the lower limit value V2 into V2 of the diagnosis function block 113. After that, the second conversion unit 170 converts the diagnostic function block 113 into a file in the object code format.

The execution unit 180 connects 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 “100”, which is the value indicating the upper limit value V1, during execution of the program, “High” is set as a value indicating 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 executing unit 180 diagnoses that the sum of the input value M and the input value N is normal if the sum is within the range specified by the information processing apparatus 200, and if the sum is outside the specified range, it is abnormal. Diagnose that there is.

As shown in FIG. 1, the information processing apparatus 200 is functionally provided with a collection setting storage unit 210 that stores data collection setting data, a collection unit 220 that collects data from a collection target, and a data analysis setting data. And an analysis setting storage unit 230 that stores the collected 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 the settings related to the data collection processing executed by the collection unit 220. The setting data stored in the collection setting storage unit 210 includes information specifying a device to be collected, information specifying the data to be collected, and a collection interval for collecting the data. The user uses the maintenance tool 500 to store these data in the information processing device 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 processing 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. Upon receiving 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 collection unit 220 acquires the data stored in the data storage unit 140 of the PLC 100. In other words, the collection 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 the setting data indicating the setting related to the analysis processing executed by the analysis unit 240. The analysis setting storage unit 230 stores, as setting data, various parameters according to each analysis method executed by the analysis unit 240. 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 the data of the unit space as a parameter of the MT method. The analysis setting storage unit 230 stores the branch target data and the threshold value thereof as the decision tree parameters. 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.

Furthermore, the analysis setting storage unit 230 stores the minimum number of pieces 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.

Upon receiving an instruction to start the collection process from the operation reception unit 510 of the maintenance tool 500, which will be described later, the analysis unit 240 causes the collection unit 220 to start the collection process. When the analysis unit 240 can start the analysis process, that is, when the start condition is satisfied, the analysis unit 240 notifies the maintenance tool 500 to that effect, for example. 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 diagnostic rule generation start instruction to the information processing apparatus 200, together with information identifying the selected analysis method.

Therefore, the analysis unit 240 starts the analysis processing by the analysis method selected by the user. Specifically, the analysis unit 240 uses the parameters stored in the analysis setting storage unit 230 for the analysis method selected by the user, and analyzes the collected data by the selected analysis method. 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 uses 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. Multiple regression analysis is performed as a variable. The analysis unit 240 outputs the estimated regression equation, the multiple correlation coefficient, the coefficient of determination, and the like to the diagnostic rule generation unit 250 as the analysis result. 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 parameter used for applying the diagnostic rule to the rule supply unit 260. The diagnostic rule defines, for example, as to a value of a certain expression, an allowable range is from where to where. For example, the diagnostic rule generation unit 250 can obtain a threshold value that determines an outlier of the value 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 value output from the FA devices 601 to 603 as the threshold value that determines 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 parameter 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 an operation received from the user and data input by the user to the PLC 100 and the information processing device 200.

Specifically, the operation accepting unit 510 causes the PLC 100 to set the setting data indicating the settings related to the data collecting process, the control program and the diagnostic program stored in the program storage unit 130, and the collecting program 211 in accordance with the user's operation instruction. Send. The operation reception unit 510 transmits, to the information processing apparatus 200, the setting data indicating the setting regarding the data collection process and the setting data indicating the setting regarding the analysis process to the information processing apparatus 200 in accordance with 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.

Next, a diagnostic rule generation process in which the information processing apparatus 200 generates a diagnostic rule will be described. The information processing device 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 of the information processing apparatus 200 shown in FIG. 1 cooperate to execute the following processing.

It is assumed that the user uses the maintenance tool 500 to instruct the PLC 100 to start the collection process. 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 uses the maintenance tool 500 to instruct the information processing apparatus 200 to start the collection process.

As shown in FIG. 7, the collection unit 220 determines, based on the data indicating the collection interval stored in the collection setting storage unit 210, whether it is time to collect data (step S11). When the collection unit 220 determines that it is time to collect data (step S11; Yes), the specified data is collected from the specified collection target (step S12), and the collected data is output to the analysis unit 240. .. Specifically, the collection unit 220 reads out the data stored in the data storage unit 140 of the PLC 100. Further, the collection unit 220 reads out data from a designated location in the memory of the FA device 603.

The analysis unit 240 determines whether or not the analysis processing 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 pieces of collected data has reached the minimum number of pieces of collected data stored in the analysis setting storage unit 230. When the analysis unit 240 determines that the analysis process can be started (step S13; Yes), the analysis unit 240 receives the designation of the analysis method from the user (step S14). For example, the 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, etc. 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 using the parameters for the analysis process stored in the analysis setting storage unit 230 (step S15).

After the analysis, the analysis unit 240 presents the analysis result to the user (step S16). The analysis unit 240 transmits the data on the screen 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 a diagnostic rule can be generated from the analysis result (step S17). When receiving 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 process of step S14 is executed again. For example, when the user's instruction received via the maintenance tool 500 is not an instruction to generate a diagnostic rule but an instruction to execute 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 under normal conditions from the analysis result of the data collected from the FA device 601. If the sum of the input value M and the input value N is within the obtained range, the diagnostic rule generation unit 250 determines to diagnose the FA device 601 as normal. If the sum of the input value M and the input value N is outside the range, the diagnosis rule generation unit 250 determines to diagnose that the FA device 601 has an abnormality. The diagnostic rule generation unit 250 obtains a value indicating the upper limit value and the 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 parameter output by the diagnostic rule generation unit 250 to the PLC 100 (step S19). The above is the processing relating to the generation of the diagnostic rule.

By executing the above-mentioned diagnostic rule generation processing, diagnostic parameters are supplied to the PLC 100. Since the PLC 100 uses the diagnostic parameters supplied from the information processing apparatus 200 to diagnose the FA device 600, it is necessary to perform the execution preparation process described below before executing the control program.

The execution preparation process is included in the initialization process executed by the PLC 100 after the PLC 100 is powered on. Therefore, the first conversion unit 160 and the second conversion unit 170 illustrated in FIG. 1 execute the execution preparation process at the timing when the power of the PLC 100 is turned on or when the PLC 100 is restarted. It is assumed that the program storage unit 130 stores a control program and a diagnostic program in advance. It is assumed that the rule receiving unit 150 has already received the diagnostic parameter 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 causes the converted diagnostic program to be executed by the execution unit 180. Output.

The first conversion unit 160 reads the 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 executable 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 changed by the switch operation of the user, the execution unit 180 executes the control program in which the diagnostic program is incorporated at each scan time. Specifically, the PLC 100 periodically acquires the input signal supplied from the FA device 600, and uses the acquired input signal to execute the program instruction. As described above, since the control program incorporates the diagnostic logic, the PLC 100 diagnoses the FA device 600 according to the diagnostic rule supplied from the information processing device 200 while executing 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 device 200 generates a diagnostic rule and supplies the PLC 100 with the diagnostic parameter used for applying the diagnostic rule. The PLC 100 executes a control program that incorporates a diagnostic program that sets parameters supplied from the information processing apparatus 200. The control system 1 having such a configuration can diagnose the control target device and immediately control the control target device based on the diagnosis result. Furthermore, 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 using the diagnostic rule suitable for the controlled object. ..

In the embodiment, the diagnostic function block 113 is used to execute the diagnostic process, so that 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. , 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. Also, when the user wants to adopt an algorithm of a diagnostic process different from the current diagnostic process, the user may save the new diagnostic functional block 113 in the PLC 100 and cause the PL1C 100 to 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 a large modification to the user program 112.

PLC 100 diagnoses FA devices 601 to 603 by executing a diagnostic function block in which diagnostic parameters supplied from information processing device 200 are set. When the diagnosis rule is changed, the information processing apparatus 200 may supply the PLC 100 with the diagnosis parameter generated from the new diagnosis rule. By executing the pre-execution process again by the PLC 100, 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. As described above, 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, although the data analysis and the generation of the diagnostic rule are processes with a high processing load, these processes are performed by the information processing device 200, not the PLC 100, and therefore the FA device that is the original process of the PLC 100. It does not affect the control processing of 601 to 603.

The analysis unit 240 has described the example of outputting the analysis result as it is to the diagnosis rule generation unit 250. However, the analysis unit 240 tests the significance of the estimated regression equation from the multiple correlation coefficient and the determination coefficient 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 diagnostic parameter is transmitted to the PLC 100, the rule supply unit 260 may notify the user of that fact. For example, the rule supply unit 260 sends to the maintenance tool 500 an email notifying that the diagnostic parameter has been sent to the PLC 100. 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 the diagnostic rule from the analysis result of the data collected from the FA device 600, the information processing device 200 cannot generate the diagnostic rule until the data is collected from the FA device 600 to some extent. The PLC 100 may store default diagnostic parameters in the memory 11. The PLC 100 can apply the default diagnostic parameters to the diagnostic function block 113 until the first diagnostic parameters are received from the information processing apparatus 200. The PLC 100 may have default diagnostic parameters in case the diagnostic parameters received from the information processing device 200 are damaged for some reason. In this case, when the diagnostic parameter received from the information processing device 200 is damaged, the PLC 100 may apply the default diagnostic parameter to the diagnostic function block 113.

In the embodiment, the example in which the information processing apparatus 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 device 200 may directly collect the data from all the FA devices 600, not via the PLC 100.

In the embodiment, the information processing apparatus 200 has been described as an example in which data collected from one PLC 100 is analyzed and a diagnostic rule is generated. However, the information processing apparatus 200 may be provided in the same factory or 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 the diagnostic rule from the result of analyzing the data collected from the FA device 600, but the invention 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 stored in advance may be data acquired from the FA device 600, or may be data acquired from a device different from the FA device 600, which is a mechanical device of the same type as the FA device 600. Good.

(Modification)
In the embodiment, an expression is set in the function block, and the information processing apparatus 200 determines whether or not the value n is within the set range based on this expression. 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, the diagnostic function block 113A includes, as a diagnostic process, "a value indicating that the equation 1 is normal when the expression 1 is within the range specified by the upper limit value V1 and the lower limit value V2. "High" is output as ", and "If Expression 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 the abnormality is present. It is assumed that and are defined.

In this case, the information processing apparatus 200 supplies 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, the diagnostic function block 113B includes, as diagnostic processing, "if expression 2 is satisfied, output "high"" and "if expression 2 is not satisfied, "Output "low"" and are 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 diagnosis target and the control target may be different devices. For example, the PLC 100 may stop the processing machine that is the control target when the PLC 100 diagnoses the transport apparatus and determines that a failure occurs in the transport apparatus. Alternatively, the control target may be included in a part of the diagnosis target.

In the embodiment, an example in which the diagnostic function block 113 outputs a value indicating normal and two values indicating abnormal is described as the result of the diagnostic process, but the present invention is not limited to this. .. For example, outputting three or more values as the diagnosis result may be defined in advance. In this case, the diagnosis function block 113 outputs any one of the defined values as the diagnosis result.

In the embodiment, an example has been described in which the information processing device 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 may not generate the diagnostic rule. For example, the information processing apparatus 200 may output the diagnostic parameter based on the diagnostic rule given in advance and the analysis result.

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

As a 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 various embodiments and modifications without departing from the broad spirit and scope. Further, the above-described embodiments are for explaining the present invention and do not limit the scope of the present invention. That is, the scope of the present invention is indicated by the scope of the claims, not the embodiments. Various modifications made within the scope of the claims and the scope of the invention equivalent thereto are considered to be within the scope of the present invention.

M, N input values, P1, P2, P3 diagnostic parameters, V1 upper limit value, V2 lower limit value, 1 control system, 11, 21, 51 memory, 12, 22 fieldbus 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 functional block, 120, 220 collecting unit, 130 program storing unit, 140 data storing unit, 150 rule receiving unit, 160 first converting unit, 170 second converting unit, 180 executing 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 device, 701, 702 network, 1131 internal interface, 1132 external interface

Claims

A control system including an information processing device that supplies diagnostic parameters used for application of a diagnostic rule for diagnosing a diagnostic target, and a programmable logic controller that diagnoses and controls the diagnostic target,
The information processing device,
Rule supply means for supplying the diagnostic parameter to the programmable logic controller,
Equipped with
The programmable logic controller is
A program including a diagnostic function block for realizing a function of a diagnostic process, the program storage unit storing a control program for executing a process for controlling a control target,
Executing means for diagnosing the diagnosis target by executing the control program including the diagnosis function block in which the diagnosis parameter is set, and controlling the control target according to a diagnosis result,
A control system including.
The programmable logic controller is
First conversion means for converting the diagnostic function block in which the diagnostic parameter is set into a format executable by the programmable logic controller;
Second conversion means for converting the control program into a format executable by the programmable logic controller;
Equipped with
The execution unit connects the diagnostic function block converted by the first conversion unit and the control program converted by the second conversion unit, and executes the combined program to diagnose the diagnosis target. Controlling the controlled object according to the diagnosis result,
The control system according to claim 1.
The control program is described in a ladder diagram, and the diagnostic function block is a componentized program described in a function block diagram,
The control system according to claim 1 or 2.
The information processing device,
Collecting means for collecting data from the diagnostic object,
Analyzing means for analyzing the data collected by the collecting means, and outputting an analysis result,
Diagnostic rule generation means for generating a diagnostic rule for diagnosing the diagnostic target and outputting the diagnostic parameter used for applying the diagnostic rule;
With
The control system according to any one of claims 1 to 3.
The collecting unit included in the information processing apparatus collects data from the diagnosis target via the programmable logic controller, or directly collects data 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 the function of the diagnostic process, the program storage unit storing a control program for executing the control process,
Rule receiving means for receiving diagnostic parameters used for applying a diagnostic rule for diagnosing a diagnostic target,
Executing means for diagnosing the diagnosis target by executing the control program incorporating the diagnosis function block in which the diagnosis parameter is set, and controlling the control target according to the diagnosis result,
A programmable logic controller including.
An information processing device, a step of supplying to the programmable logic controller diagnostic parameters used to apply a diagnostic rule for diagnosing a diagnostic target of the programmable logic controller,
The programmable logic controller, the step of setting the diagnostic parameters in a diagnostic function block for realizing the function of diagnostic processing,
The programmable logic controller, a step of coupling the diagnostic parameter to a control program for executing a process of controlling a controlled object,
A step of diagnosing the diagnosis target by the programmable logic controller executing the control program to which the diagnostic function block is coupled;
The programmable logic controller, by executing the control program, a step of controlling the controlled object,
Including the method.
A control program for executing processing for controlling the controlled object,
A diagnostic function block that is a functional block incorporated in the control program, in which a diagnostic parameter used to apply a diagnostic rule for diagnosing a diagnostic target is set, and that implements a diagnostic processing function,
Including
The diagnostic function block includes an internal interface unit for connecting the diagnostic function block to the control program, and an external interface unit for receiving the diagnostic parameter.
On the computer,
Diagnose the diagnosis target,
Control the controlled object according to the diagnosis result,
program.