CN113424115A

CN113424115A - Control system, programmable logic controller, method, and program

Info

Publication number: CN113424115A
Application number: CN201980091574.5A
Authority: CN
Inventors: 那须督; 渡边大介
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2019-02-14
Filing date: 2019-02-14
Publication date: 2021-09-21
Also published as: WO2020166004A1; JPWO2020166004A1

Abstract

A control system (1) comprises: an information processing device (200) that supplies diagnostic parameters used for application of diagnostic rules for diagnosing FA apparatuses (601, 602, 603); and a PLC (100) which diagnoses and controls the FA apparatuses (601, 602, 603). A rule supply unit (260) of the information processing device (200) supplies the diagnostic parameter to the programmable logic controller. A program storage unit (130) of a PLC (100) stores a control program for executing processing for controlling an FA apparatus (601, 602, 603), the control program including a diagnostic function module for realizing a function of diagnostic processing. An execution unit (180) of the PLC (100) diagnoses the FA apparatuses (601, 602, 603) by executing a control program including a diagnostic function module in which diagnostic parameters are set, and controls the FA apparatuses (601, 602, 603) in accordance with the diagnosis result.

Description

Control system, programmable logic controller, method, and program

Technical Field

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

Background

In a factory, a workshop, or the like that is a production site, for the purpose of preventive maintenance of equipment, improvement of manufacturing quality, and the like, a programmable logic controller may diagnose a machine used in a production process, an inspection process, and other processes in cooperation with a host system that manages the programmable logic controller.

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 diagnostic rule supplied from the host system and the data collected from the device to be diagnosed, and outputs an alarm corresponding to the result of the diagnosis.

Patent document 1: japanese laid-open patent publication No. 2002-062933

Disclosure of Invention

In the configuration described in patent document 1, after the field device outputs an alarm conforming to the diagnosis result, for example, an operator needs to apply the necessary treatment to the corresponding device. In this case, after the field device outputs an alarm, the operator cannot perform a treatment on the corresponding device immediately in many cases. Therefore, a time difference occurs between the diagnosis of the instrument and the control of the instrument.

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

In order to achieve the above object, a control system according to the present invention includes: an information processing device that supplies diagnostic parameters used for application of a diagnostic rule for diagnosing a diagnostic object; and a programmable logic controller for diagnosing and controlling the diagnostic object. A diagnostic rule supply unit provided in the information processing device supplies the diagnostic parameter to the programmable logic controller. A program storage unit included in the programmable logic controller stores a control program for executing a process of controlling a control target, the control program including a diagnostic function module for realizing a function of a diagnostic process. The execution unit of the programmable logic controller diagnoses the diagnosis target by executing a control program including a diagnosis function module in which the diagnosis parameter is set, and controls the control target in accordance with the diagnosis result.

ADVANTAGEOUS EFFECTS OF INVENTION

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

Drawings

Fig. 1 is a functional block diagram of each device included in a control system according to an embodiment of the present invention.

Fig. 2 is a diagram showing a hardware configuration of each device included in the control system according to the embodiment.

Fig. 3 is a diagram showing an example of a user program according to the embodiment.

Fig. 4 is a diagram for explaining the configuration of the program storage unit and the 2 nd conversion unit of the programmable logic controller according to the embodiment.

Fig. 5 is a diagram showing an example of a diagnostic function module according to the embodiment.

Fig. 6 is a diagram showing an example of the diagnostic parameters according to the embodiment.

Fig. 7 is a flowchart of a diagnostic rule generation process according to the embodiment.

Fig. 8 is a flowchart of the execution preparation processing according to the embodiment.

Fig. 9A is a diagram showing an example of a diagnostic function module according to a modification.

Fig. 9B is a diagram showing an example of the diagnostic parameters according to the modification.

Fig. 10A is a diagram showing an example of another diagnostic function module according to a modification.

Fig. 10B is a diagram showing another example of the diagnostic parameters according to the modification.

Detailed Description

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

(embodiment mode)

The control system 1 shown in fig. 1 includes: a programmable logic controller 100 for controlling the FA apparatuses 601 to 603; an information processing apparatus 200 that generates a diagnostic rule; and a maintenance tool 500 for operation of the programmable logic controller by a user.

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

FA apparatuses

601, 602, and 603 in the production system.

FA instruments

601, 602, and 603 are mechanical devices that operate in a production line. The PLC 100 executes a control program to control the

FA apparatuses

601, 602, and 603. Specifically, the PLC 100 performs an operation using a value indicated by the input signal supplied from the

FA apparatuses

601, 602, and 603 by executing each command of the control program for each set cycle, that is, each scanning time, and supplies an output signal based on the value indicating the operation result to the

FA apparatuses

601, 602, and 603. Hereinafter, the

FA apparatuses

601, 602, and 603 are sometimes collectively referred to as an FA apparatus 600.

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

The information processing apparatus 200 collects data via the PLC 100 or directly from the FA device 600, and analyzes the collected data. Then, the information processing device 200 generates a diagnostic rule for diagnosing the FA equipment 600 based on the analysis result, and supplies a diagnostic parameter, which is a parameter used for applying the generated diagnostic rule, to the PLC 100. The information processing apparatus 200 performs analysis and generation of a diagnostic rule before the PLC 100 starts execution of the control program. For example, an Industrial PC (Industrial Personal Computer: IPC) is used as the information processing device 200.

The diagnostic process executed by the PLC 100 is diagnosed as normal when, for example, a value indicating the calculation result falls within a specified range, and is diagnosed as abnormal when the value falls outside the specified range. When the PLC 100 performs such a diagnosis process, the information processing device 200 obtains the upper limit value and the lower limit value of the predetermined range from the analysis result, and supplies the obtained condition value and the lower limit value to the PLC 100 as diagnosis parameters.

The maintenance tool 500 is a tool for operating the PLC 100 by a user. The user creates a program required for controlling the FA equipment 600 using the maintenance tool 500, and stores the created program in the PLC 100. Then, the user uses the maintenance tool 500 to store data necessary for the operation of each of the PLC 100 and the information processing apparatus 200 in the PLC 100 and the information processing apparatus 200. As the maintenance tool 500, for example, a personal computer installed with a dedicated application provided in the same factory as the FA equipment 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 field bus interface 12 that communicates with other devices via a network 701; an information-based network interface 13 that communicates with other devices via a network 702; and an mpu (micro Processing unit)14 that controls the entire PLC 100. The memory 11, the field bus interface 12, and the information-based network interface 13 are connected to the MPU 14 via a bus 19, and each communicates with the MPU 14.

The memory 11 includes a volatile memory and a nonvolatile memory. The memory 11 stores programs for implementing various functions of the PLC 100. Specifically, the memory 11 stores a collection program 111, a user program 112, and a diagnostic function module 113. Also, the memory 11 is used as a work memory of the MPU 14.

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

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 as a ladder diagram. The user program 112 is a program created by a user.

The diagnostic function module 113 is a circuit module relating to a diagnostic process that is repeatedly used in the user program 112, and is formed by combining circuit modules. The diagnostic function module 113 is illustrated as a function module diagram. The diagnostic function module 113 is created by the manufacturer of the PLC 100. The memory 11 may store 2 or more diagnostic function modules 113. The diagnostic function module 113 is an example of the diagnostic function module of the present invention.

In the embodiment, as shown in fig. 3, the user creates the user program 112 in which the function module 113 for diagnosis is installed. Therefore, the PLC 100 can diagnose and control the FA equipment 600 by sequentially executing the commands of the user program 112.

The field bus 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 specification.

The information 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 the specifications of 10BASE-T and 100BASE-T, for example.

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 a specified collection target. The MPU 14 executes the user program 112 embedded with the diagnostic function module 113 to control and diagnose the FA equipment 600.

The information processing apparatus 200 has, as a hardware configuration: a memory 21 that stores various programs and data; a field bus interface 22 that communicates with other devices via a network 701; an information-based network interface 23 that communicates with other devices via a network 702; and a cpu (central Processing unit)24 that controls the entire information Processing apparatus 200. The memory 21, the field bus interface 22, and the information network interface 23 are connected to the CPU 24 via a bus 29, and each communicate with the CPU 24.

The memory 21 includes a volatile memory and a nonvolatile memory. The memory 21 stores programs for realizing various functions of the information processing apparatus 200. Specifically, the memory 21 stores a collection program 211, an analysis program 212, and a rule generation program 213. Also, the memory 21 is used as a work memory of 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 object. The analysis program 212 is a program for causing the information processing apparatus 200 to realize a function of analyzing the collected data. The rule generation program 213 is a program for causing the information processing apparatus 200 to realize a function of generating a diagnosis rule based on the analysis result.

The fieldbus interface 22 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 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.

CPU 24 executes various programs stored in memory 21 to realize various functions of information processing apparatus 200. Specifically, the CPU 24 executes the collection program 211 to collect data from a specified collection target. CPU 24 executes analysis program 212 to analyze the collected data. The CPU 24 executes the rule generation program 213, 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, as a hardware configuration: a memory 51 for storing various programs and data; an information-based network interface 52 that communicates with other devices via a network 702; an input-output device 53, which is a user interface; 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 each communicate with the CPU 54.

The memory 51 includes volatile memory and nonvolatile memory. The memory 51 stores programs for implementing various functions of the maintenance tool 500. Specifically, the memory 51 stores the maintenance program 511. In addition, 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 causes the maintenance tool 500 to realize a function of transmitting data necessary for the operation of the PLC 100 and the information processing apparatus 200 to the PLC 100 and the information processing apparatus 200. The data transmitted from the maintenance tool 500 to the PLC 100 includes various setting data necessary for the collection program 111, the user program 112, the diagnostic function module 113, and the data collection process. The data transmitted from the maintenance tool 500 to the information processing apparatus 200 includes various setting data necessary for data collection processing and various setting data necessary for analysis processing.

The maintenance program 511 also 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 apparatus 200. The maintenance program 511 realizes a function of transmitting an instruction to start the rule generation process 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 apparatus 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 the 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 a signal supplied from the CPU 54.

The CPU 54 executes the maintenance program 511 to implement 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 apparatus 200 to the PLC 100 and the information processing apparatus 200 in accordance with an operation instruction from a user. The CPU 54 transmits an instruction to start data collection processing to the PLC 100 and the information processing apparatus 200 in accordance with an operation instruction from the user. The CPU 54 receives a specification of an analysis method in accordance with an operation instruction from a user, and executes analysis processing of collected data. CPU 54 transmits an instruction to start rule generation processing to information processing apparatus 200 in accordance with an operation instruction from the user.

Next, a functional configuration of each device included in the control system 1 will be described with reference to fig. 1. 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; a data storage unit 140 that stores the collected data; a rule receiving unit 150 that receives the diagnostic parameter from the information processing device 200; a 1 st conversion unit 160 that converts the control program; a 2 nd conversion unit 170 for converting the diagnostic program; and an execution unit 180 that executes the control program and the diagnostic program.

The collection setting storage unit 110 stores setting data indicating settings related to the data collection process performed 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 collected data, 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. 2.

The collection unit 120 shown in fig. 1 collects data in accordance with the settings related to the data collection process stored in the collection setting storage unit 110. Specifically, the collecting unit 120 collects specified data from a specified collection target at specified collection intervals, and stores the collected data in the data storage unit 140. In the illustrated example, the collection unit 120 collects data from the

FA apparatuses

601 and 602. The collection unit 120 starts the collection process if receiving a collection start instruction from the operation receiving unit 510 of the maintenance tool 500 described later. Hereinafter, the data collected by the collection unit 120 and the collection unit 220 of the information processing device 200 described later may be referred to as collected data. The collected data includes data acquired by sensors such as a vibration sensor, a temperature sensor, a pressure sensor, and a flow sensor provided in the FA apparatus 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 unit of the present invention.

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

As described above, the user program 112 is embedded with the diagnostic function module 113. Therefore, as shown in fig. 4, the program storage unit 130 includes a function module execution definition 112a in the user program 112. When the program is executed, the user program 112 and the diagnostic function module 113 are combined via the internal interface 1131. Therefore, the diagnostic function module 113 is called from the user program 112 and executed. The calling method of the diagnostic function module 113 from the user program 112 and the transmission method of the diagnostic result from the diagnostic function module 113 to the user program 112 are defined in advance as the specifications of the PLC 100. The diagnostic function module 113 has an internal interface 1131, which is a function unit having a function based on the definition. The internal interface 1131 is an example of an internal interface unit according to the present invention. The diagnostic function module 113 also has an external interface 1132 that receives diagnostic parameters. The external interface 1132 will be described later.

The diagnostic function module 113 includes definition information defining the contents of diagnostic processing and definition information relating to diagnostic parameters. In the example shown in fig. 5, the diagnostic function module 113 is defined as "when the sum of the input value M and the input value N is within the range defined by the upper limit value V1 and the lower limit value V2," high "is output as a value indicating normal" and "when the sum of the input value M and the input value N is outside the range defined by the upper limit value V1 and the lower limit value V2," low "is output as a value indicating abnormal" as the diagnostic process.

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

The diagnostic parameters supplied from the information processing apparatus 200 are parameters used for diagnostic processing for applying the diagnostic rule generated by the information processing apparatus 200 to the diagnosis of the control target by the PLC 100.

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. 2. The collecting unit 220 is an example of the collecting unit of the present invention.

The rule receiving unit 150 shown in fig. 1 receives the diagnostic parameter from the information processing device 200, and outputs the received diagnostic parameter to the 2 nd conversion unit 170. Since the timing at which the information processing device 200 transmits the diagnostic parameters to the PLC 100 and the timing at which the 2 nd conversion unit 170 converts the diagnostic program into the executable format are different, the diagnostic parameters received by the rule reception unit 150 are actually stored in the memory 11, and the 2 nd conversion unit 170 reads the diagnostic parameters stored in the memory 11. The function of the rule receiving unit 150 is realized by the information network interface 13 and the MPU 14 shown in fig. 2. The rule receiving unit 150 is an example of the rule receiving unit of the present invention.

The 1 st 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 as a ladder diagram. Specifically, the 1 st conversion unit 160 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 1 st conversion unit 160 is realized by the MPU 14 shown in fig. 2. The 1 st converting unit 160 is an example of the 1 st converting means of the present invention.

As shown in fig. 4, the 2 nd conversion unit 170 shown in fig. 1 applies the diagnostic parameter P1 received from the information processing device 200 by the rule receiving unit 150 to the diagnostic function module 113 stored in the program storage unit 130 via the external interface 1132. The method of applying the diagnostic parameter P1 to the diagnostic function module 113 is defined in advance as a specification of the PLC 100. The external interface 1132 is a functional unit to which functions are attached based on the definition. The external interface 1132 is an example of an external interface unit according to the present invention.

The 2 nd conversion unit 170 converts the diagnostic program to which the diagnostic parameters are 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 module 113 shown in fig. 2 corresponding to the diagnostic program is described as a function module diagram. Specifically, the 2 nd conversion unit 170 converts a file obtained by substituting the diagnostic parameter received from the information processing device 200 into the diagnostic function module 113 into a file in the target code format, and stores the converted diagnostic function module 113 in the memory 11. The function of the 2 nd conversion unit 170 is realized by the MPU 14 shown in fig. 2. The 2 nd converting unit 170 is an example of the 2 nd converting means of the present invention.

For example, the diagnostic processing as shown in fig. 5 is defined in the diagnostic function module 113. Here, a value indicating upper limit value V1 and a value indicating lower limit value V2 are supplied as diagnostic parameters from information processing apparatus 200. In this case, the 2 nd converting unit 170 substitutes the value representing the upper limit value V1 and the value representing the lower limit value V2 into the upper limit value V1 and the lower limit value V2 of the diagnostic function module 113, and converts the diagnostic function module 113 into a file in the target code format.

The execution unit 180 shown in fig. 1 diagnoses and controls the FA instrument 600 by combining the converted control program output from the 1 st conversion unit 160 and the diagnostic program output from the 2 nd conversion unit 170 and executing the combined program. Specifically, the execution unit 180 executes a program in which the converted user program 112 stored in the memory 11 by the 1 st conversion unit 160 and the converted diagnostic function module 113 stored in the memory 11 by the 2 nd conversion unit 170 are combined. The function of execution unit 180 is realized by MPU 14 shown in fig. 2. The execution unit 180 is an example of an execution unit of the present invention.

A diagnostic function module 113 as shown in fig. 5 is embedded in the user program 112 shown in fig. 3. From the information processing apparatus 200 to the PLC 100, "100" is supplied as the upper limit value V1 and "20" is supplied as the lower limit value V2 as the diagnostic parameter P1 shown in fig. 6. An example of the operation of each of the 1 st converting unit 160, the 2 nd converting unit 170, and the executing unit 180 in this case will be described.

The 1 st conversion unit 160 converts the user program 112 into a file in an object code format. The 2 nd converter 170 substitutes a value "100" indicating the upper limit value V1 for V1 of the diagnostic function module 113 and substitutes a value "20" indicating the lower limit value V2 for V2 of the diagnostic function module 113. Then, the 2 nd conversion unit 170 converts the diagnostic function module 113 into a file in the target code format.

The execution unit 180 combines the user program 112 converted by the 1 st conversion unit 160 and the diagnostic function module 113 converted by the 2 nd conversion unit 170, and executes the combined program. During execution of the program, if the execution unit determines that the sum of the input value M and the input value N is greater than "100", which is a value indicating the upper limit value V1, the execution unit outputs "high" as a value indicating normal. Then, if it is determined that the sum of input value M and input value N is smaller than value "20" indicating lower limit value V2, execution unit 180 outputs "low" as a value indicating an abnormality. As a result, "command 004" shown in fig. 3 is not executed. In this way, the execution unit 180 diagnoses that the input value M and the input value N are normal if the sum is within the range specified by the information processing device 200, and diagnoses that the input value M and the input value N are abnormal if the sum is outside the specified range.

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

The collection setting storage unit 210 stores setting data indicating settings related to the data collection process performed 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 collected data, and a collection interval for collecting data. The user uses the maintenance tool 500 to store the 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. 2.

The collection unit 220 shown in fig. 1 collects data in accordance with the settings related to the data collection process stored in the collection setting storage unit 210. Specifically, the collection unit 220 collects specified data from a specified collection target at specified collection intervals, and outputs the collected data to the analysis unit 240. The collection unit 220 starts the collection process if receiving a start instruction of collection from the user via the maintenance tool 500.

In the illustrated example, the collection unit 220 directly collects data from the FA equipment 603. The collection unit 220 acquires data stored in the data storage unit 140 of the PLC 100. In other words, the collection unit 220 collects data from the

FA apparatuses

601 and 602 via the PLC 100. The function of the collection unit 220 is realized by executing the collection program 211 by the CPU 24 shown in fig. 2.

The analysis setting storage unit 230 stores setting data indicating settings related to the analysis process performed 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 target variables, explanatory variables, initial values of partial regression coefficients, and the like as parameters for multiple regression analysis. The analysis setting storage unit 230 stores the data of the unit space as parameters of the MT method. The analysis setting storage unit 230 stores data of the branch target and the threshold thereof as parameters for determining the 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. 2.

The analysis setting storage unit 230 stores the minimum number of pieces of data required to collect the collected data. This data amount is a starting condition for the analysis unit 240 to start the analysis process.

Upon receiving an instruction to start the collection process from the operation receiving 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. If the analysis process can be started, that is, if the start condition is satisfied, the analysis unit 240 notifies this to the maintenance tool 500, for example. In response to this, the operation receiving unit 510 of the maintenance tool 500 displays a selection screen of the analysis method on the display of the input/output device 53. If the user selects a desired analysis method, the operation receiving unit 510 transmits a start instruction of the diagnosis rule generation to the information processing apparatus 200 together with information for specifying the selected analysis method.

Therefore, the analysis unit 240 starts analysis processing 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 diagnosis rule generation unit 250.

For example, when the user designates the multiple regression analysis as the analysis method, the analysis unit 240 performs the multiple regression analysis using the value designated by the user in the collected data as the target variable and the value designated by the user in the collected data as the explanatory variable. The analysis unit 240 outputs the estimated regression expression, multiple correlation coefficient, decision coefficient, and the like to the diagnostic rule generation unit 250 as an 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 an analysis means of the present invention.

The diagnostic rule generating unit 250 generates a diagnostic rule based on the analysis result output from the analyzing unit 240, and outputs a diagnostic parameter used for applying the diagnostic rule to the rule supplying unit 260. The diagnostic rule is, for example, a value as a certain formula, and specifies where to where the allowable range is. For example, the diagnostic rule generating unit 250 can determine a threshold value for determining the deviation value of the value output from the FA apparatuses 601 to 603 from an estimated regression model represented by a regression expression output from the analyzing unit 240. The diagnostic rule generating unit 250 determines the upper limit value and the lower limit value of each of the values output from the FA apparatuses 601 to 603 as a threshold value for determining the deviation value. The function of the diagnostic rule generating unit 250 is realized by the CPU 24 shown in fig. 2 executing the rule generating program 213. The diagnostic rule generating unit 250 is an example of the diagnostic rule generating means of the present invention.

The rule supply unit 260 shown in fig. 1 transmits the diagnostic parameter output from the diagnostic rule generation unit 250 to the rule reception unit 150 of the PLC 100. The function of the rule supply unit 260 is realized by the information network interface 23 and the CPU 24 shown in fig. 2. The rule supply unit 260 is an example of the rule supply unit of the present invention.

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

Specifically, the operation receiving unit 510 transmits setting data indicating 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 to the PLC 100 in accordance with an operation instruction from the user. The operation receiving unit 510 transmits setting data indicating settings related to the data collection process and setting data indicating settings related to the analysis process to the information processing apparatus 200 in accordance with an operation instruction from the user.

The operation receiving unit 510 transmits a signal indicating a start instruction of data collection received from the user to the PLC 100 and the information processing apparatus 200. The operation receiving unit 510 transmits the start instruction of the diagnostic rule generation received from the user to the information processing apparatus 200 together with information indicating the analysis method selected by the user. The function of the operation receiving section 510 is realized by the CPU 54 shown in fig. 2.

Next, a diagnostic rule generation process for generating a diagnostic rule by the information processing device 200 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, and the diagnosis rule generation unit 250 of the information processing apparatus 200 shown in fig. 1 cooperate with the collection unit 120 of the PLC 100 to execute the following processes.

The user indicates to the PLC 100 the start of the collection process using the maintenance tool 500. Therefore, the collection unit 120 of the PLC 100 collects data from the

FA apparatuses

601 and 602 at a predetermined collection interval, and stores the collected data in the data storage unit 140. Further, the user instructs the information processing apparatus 200 to start the collection process using the maintenance tool 500.

As shown in fig. 7, the collection unit 220 determines whether or not the data is collected at a timing based on the data indicating the collection interval stored in the collection setting storage unit 210 (step S11). If it is determined that the data is collected at a timing (Yes; step S11), the collection unit 220 collects the designated data from the designated collection target (step S12), and outputs the collected data to the analysis unit 240. Specifically, the collection unit 220 reads data stored in the data storage unit 140 of the PLC 100. The collection unit 220 reads data from a predetermined position 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 minimum number of data that needs to be collected and stored in the analysis setting storage unit 230. If it is determined that the analysis process can be started (step S13; Yes), the analysis unit 240 receives a designation of an 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. The user selects a desired analysis method using a keyboard, a mouse, or the like of the input/output device 53. The analysis unit 240 executes analysis processing of the collected data for the analysis method selected by the user using the parameters for the analysis processing stored in the analysis setting storage unit 230 (step S15).

If the analysis is completed, the analysis unit 240 presents the analysis result to the user (step S16). The analysis unit 240 transmits data on a screen indicating the analysis result to the maintenance tool 500 shown in fig. 2. In response to this, the CPU 54 of the maintenance tool 500 displays the received data of the screen on the display of the input/output device 53.

As shown in fig. 7, the analysis unit 240 determines whether or not the diagnosis 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. If it is determined 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, if it is determined 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, when the instruction of the user received via the maintenance tool 500 is not an instruction to generate the diagnostic rule but an instruction to perform the analysis again, the analysis unit 240 performs the process of step S14 again.

In step S18, the diagnostic rule generator 250 generates a diagnostic rule (step S18). Here, it is assumed that the control target is the FA apparatus 601. For example, the diagnostic rule generating unit 250 obtains a range expected as a value that is the sum of the input value M and the input value N in the normal state, based on the analysis result of the data collected from the FA equipment 601. The diagnostic rule generating unit 250 determines that the FA equipment 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 diagnostic rule generating unit 250 determines that an abnormality has occurred in the FA equipment 601. The diagnostic rule generating unit 250 obtains values indicating the upper limit and the lower limit of the range, and outputs the obtained values to the rule supplying unit 260 as diagnostic parameters.

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

By executing the diagnostic rule generation processing described above, the diagnostic parameters are supplied to the PLC 100. Since the PLC 100 diagnoses the FA equipment 600 using the diagnostic parameters supplied from the information processing device 200, it is necessary to perform the execution preparation process described below before the execution of the control program.

The execution preparation process includes initialization processing executed by the PLC 100 after the PLC 100 is powered on. Therefore, at the timing when the PLC 100 is powered on or when the PLC 100 is restarted, the 1 st conversion unit 160 and the 2 nd conversion unit 170 shown in fig. 1 execute the preparation process. The program storage unit 130 stores a control program and a diagnostic program in advance. The rule receiving part 150 has received the diagnostic parameters from the information processing apparatus 200.

As shown in fig. 8, the 2 nd conversion unit 170 reads out the diagnostic program from the program storage unit 130 (step S21). The 2 nd conversion unit 170 sets the diagnostic parameters stored in the memory 11 in the diagnostic program, converts the diagnostic program into a format executable by the PLC 100 (step S22), and outputs the converted diagnostic program to the execution unit 180.

The 1 st converting unit 160 reads the control program from the program storage unit 130 shown in fig. 1 (step S23). The 1 st 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 files in the target code format converted by the user program 112 and the files in the target code format converted by the diagnostic function module 113 shown in fig. 2. The above prepares the processing involved for execution.

After that, if the operation mode is changed to the operation mode by the user's switch operation, the execution unit 180 executes the control program in which the diagnostic program is embedded for each scanning time unit. Specifically, the PLC 100 periodically acquires an input signal supplied from the FA device 600, and executes a command of a program using the acquired input signal. As described above, since the control program is embedded with the diagnosis logic, the PLC 100 can diagnose the FA apparatus 600 in accordance with the diagnosis rule supplied from the information processing device 200 during execution of the control program, and control the FA apparatus 600 in accordance with the diagnosis result.

As described above, in the control system 1 according to the embodiment, the information processing device 200 generates the diagnostic rule and supplies the PLC 100 with the diagnostic parameter used for applying the diagnostic rule. The PLC 100 executes a control program in which a diagnostic program in which parameters supplied from the information processing device 200 are set is embedded. With 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. Furthermore, since the information processing device 200 generates the diagnostic rule based on the result of analyzing the data collected from the control target, the PLC 100 can appropriately diagnose the control target using the diagnostic rule suitable for the control target.

In the embodiment, since the diagnostic process is executed using the functional module for diagnosis 113, there are the following advantages. If the internal interface 1131 for connecting the user program 112 and the diagnostic function module 113 is not changed, the diagnostic function can be changed by changing the called diagnostic function module 113 only by changing the function module execution definition 112a in the user program 112.

As described above, the function module 113 for diagnosis 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 store a new diagnostic function block 113 in the PLC 100 and cause the PL1C100 to execute the preparatory process again. In addition, when the user wants to use an algorithm of a diagnosis process different from the current diagnosis process, the user may store a new diagnosis function module 113 in the PLC 100 and cause the PLC 100 to execute the preparatory process again. The user can use a new diagnostic function module 113 for the user program 112 without changing the function module execution definition 112a in the user program 112. Thus, the user does not need to apply large corrections to the user program 112.

The PLC 100 diagnoses the FA apparatuses 601 to 603 by executing a diagnostic function block in which a diagnostic parameter supplied from the information processing device 200 is set. When the diagnostic rule is changed, the information processing device 200 may supply the PLC 100 with the diagnostic parameter generated based on the new diagnostic rule. By executing the preprocessing again by the PLC 100, a new diagnostic parameter 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 device 200 changes the diagnostic rule, the PLC 100 can apply the changed diagnostic rule in a simple manner.

Further, although the analysis of data and the generation of the diagnostic rule are processing with a high processing load, the PLC 100 does not execute these processing and is executed by the information processing device 200, and therefore the control processing of the FA apparatuses 601 to 603, which is the processing inherent to the PLC 100, is not affected.

Although the example in which the analysis unit 240 directly outputs the analysis result to the diagnostic rule generation unit 250 has been described, the analysis unit 240 may identify the validity of the estimated regression expression based on the multiple correlation coefficient and the determination coefficient after the analysis. The analysis unit 240 may output the analysis result to the diagnostic rule generation unit 250 when the regression expression is valid.

The rule supply unit 260 may notify the user of the diagnosis parameter when the diagnosis parameter is transmitted to the PLC 100. For example, the rule supply unit 260 transmits a mail notifying that the diagnostic parameter is transmitted to the PLC 100 to the maintenance tool 500. If the user receives a notification that the diagnostic parameter is transmitted to the PLC 100, the PLC 100 is restarted and the latest diagnostic parameter can be applied to the diagnostic function module 113.

In addition, since the information processing apparatus 200 generates the diagnostic rule based on the analysis result of the data collected from the FA device 600, the diagnostic rule cannot be generated until the data is collected from the FA device 600 to some extent. The PLC 100 may also store default diagnostic parameters in the memory 11. The PLC 100 can apply default diagnostic parameters to the diagnostic function module 113 before receiving the first diagnostic parameters from the information processing apparatus 200. In addition, in case the diagnostic parameters received from the information processing apparatus 200 are damaged for some reason, the PLC 100 may have default diagnostic parameters. In this case, when the diagnostic parameter received from the information processing apparatus 200 is damaged, the PLC 100 may apply a default diagnostic parameter to the diagnostic function module 113.

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

In the embodiment, the example in which the information processing apparatus 200 analyzes data collected from 1 PLC 100 to generate a diagnostic rule has been described, but the information processing apparatus 200 may collect data from a plurality of PLCs in the same plant or in different plants and generate a diagnostic rule based on the analysis result of the collected data.

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

(modification example)

In the embodiment, the example has been described in which the formula is set in the functional module, and whether or not the value n is within the set range is determined by the formula, and therefore the information processing apparatus 200 supplies the upper limit value and the lower limit value as the diagnosis parameters to the PLC 100, but the invention is not limited to this. As the diagnostic parameter, the information processing apparatus 200 may supply the formula instead of the value.

For example, as shown in fig. 9A, it is defined that "in the case where equation 1 is within the range determined by the upper limit value V1 and the lower limit value V2, 'high' is outputted as a value indicating normality" and "in the case where equation 1 is outside the range determined by the upper limit value V1 and the lower limit value V2, 'low' is outputted as a value indicating abnormality" as the diagnosis process for the diagnostic function module 113A.

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.

For example, as shown in fig. 10A, the diagnostic function module 113B is defined as "output high" when equation 2 is satisfied "and" output low "when equation 2 is not satisfied" as the diagnostic process.

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 apparatus 600 is a diagnosis target and a control target of the PLC 100, and the diagnosis target and the control target are the same. The diagnostic object and the control object may also be different instruments. For example, the PLC 100 may diagnose the transport device and stop the processing machine as the control target if it is determined that a failure has occurred in the transport device. Alternatively, a part of the diagnosis target may include the control target.

In the embodiment, the example in which the diagnostic function module 113 outputs two values, that is, the value indicating the normality and the value indicating the abnormality, as the result of the diagnostic processing has been described, but the present invention is not limited to this. For example, as a result of diagnosis, it is also possible to define in advance that the output is greater than or equal to 3 values. In this case, the diagnostic function module 113 outputs any of the defined values as a diagnostic result.

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

In the embodiment, an example in which an industrial PC is used as the information processing apparatus 200 is described, but the present invention is not limited thereto. As the information processing apparatus 200, a personal computer may be used, or a server on the cloud may be used.

In the embodiment, the example in which the personal computer having the dedicated application installed therein is used as the maintenance tool 500 is described, but the present invention is not limited thereto. For example, a computer functioning as the information processing apparatus 200 may also function as the maintenance tool 500. Alternatively, a server on the cloud may also function as the maintenance tool 500.

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

The present invention can be embodied in various forms and modifications without departing from the spirit and scope of the invention in its broadest form. The above embodiments are provided to illustrate the present invention, and do not limit the scope of the present invention. That is, the scope of the present invention is indicated not by the embodiments but by the claims. Further, various modifications made within the scope of the claims and within the meaning equivalent thereto are considered to fall within the scope of the present invention.

Description of the reference numerals

M, N input values, P1, P2, P3 diagnostic parameters, V1 upper limit value, V2 lower limit value, 1 control system, 11, 2151 memory, 12, 22 field bus interface, 13, 23, 52 information network interface, 14MPU, 19, 29, 59 bus, 24, 54CPU, 53 input/output device, 100 Programmable Logic Controller (PLC), 110, 210 collection setting storage unit, 111, 211 collection program, 112 user program, 112a function module execution definition, 113A, 113B diagnostic function module, 120, 220 collection unit, 130 program storage unit, 140 data storage unit, 150 rule receiving unit, 160 st transformation unit, 170 nd transformation 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 receiving unit, 511 maintenance program, 601-603 (600) FA instrument, 701, 702 network, 1131 internal interface, 1132 external interface.

Claims

1. A control system, comprising: an information processing device that supplies diagnostic parameters used for application of a diagnostic rule for diagnosing a diagnostic object; and a programmable logic controller for diagnosing and controlling the diagnostic object,

in the case of the control system in this manner,

the information processing apparatus has a rule supply unit that supplies the diagnostic parameter to the programmable logic controller,

the programmable logic controller has:

a program storage unit that stores a control program for executing a process of controlling a control target, the control program including a diagnostic function module for realizing a function of a diagnostic process; and

and an execution unit that diagnoses the diagnostic object by executing the control program including the diagnostic function module in which the diagnostic parameter is set, and controls the control object in accordance with a diagnosis result.

2. The control system of claim 1,

the programmable logic controller has:

a 1 st conversion unit that converts the diagnostic function module in which the diagnostic parameter is set into a format executable by the programmable logic controller; and

a 2 nd conversion unit that converts the control program into a format executable by the programmable logic controller,

the execution unit diagnoses the diagnostic object by combining the diagnostic function module converted by the 1 st conversion unit and the control program converted by the 2 nd conversion unit and executes the combined program, and controls the control object according to the diagnosis result.

3. The control system according to claim 1 or 2, wherein,

the control program is described in a ladder diagram, and the diagnostic function block is a block-based program described in a function block diagram.

4. The control system according to any one of claims 1 to 3,

the information processing apparatus includes:

a collection unit that collects data from the diagnostic object;

an analysis unit configured to analyze the data collected by the collection unit and output an analysis result; and

and a diagnostic rule generation unit that generates a diagnostic rule for diagnosing the diagnostic object and outputs the diagnostic parameter used for application of the diagnostic rule.

5. The control system of claim 4,

the collection unit included in the information processing apparatus collects data from the diagnostic object via the programmable logic controller, or collects data directly from the diagnostic object.

6. The control system according to any one of claims 1 to 5,

the control object includes the diagnostic object.

7. The control system according to any one of claims 1 to 5,

the control object does not include the diagnostic object.

8. A programmable logic controller having:

a program storage unit that stores a control program for executing control processing, the control program including a diagnostic function module for realizing a function of diagnostic processing;

a rule receiving unit that receives a diagnostic parameter used for application of a diagnostic rule for diagnosing a diagnostic object; and

and an execution unit configured to diagnose the diagnostic object by executing the control program in which the diagnostic function module in which the diagnostic parameter is set is embedded, and to control the control object in accordance with a diagnosis result.

9. A method comprising the steps of:

an information processing device supplies, to a programmable logic controller, a diagnostic parameter used for application of a diagnostic rule for diagnosing a diagnostic object of the programmable logic controller;

the programmable logic controller sets the diagnostic parameters to a diagnostic function module for implementing a function of a diagnostic process;

the programmable logic controller incorporating the diagnostic parameter into a control program for executing a process of controlling a control object;

the programmable logic controller executing the control program in conjunction with the diagnostic function module to diagnose the diagnostic subject; and

the programmable logic controller executes the control program to control the control object.

10. A process, comprising:

a control program for executing a process of controlling a control target; and

a diagnostic function module embedded in the control program, the diagnostic function module being configured to set a diagnostic parameter used for application of a diagnostic rule for diagnosing a diagnostic object, the diagnostic function module implementing a function of a diagnostic process,

the diagnostic function module has:

an internal interface unit for connecting the diagnostic function module to the control program; and

an external interface unit which receives the diagnostic parameter,

the program causes a computer to diagnose a diagnosis target and control the control target according to a diagnosis result.